Weld M4.

xmcd [Pg 1 / 8]

Welding (pg 784)

Due to lower initial cost, many structural parts of a machinery formerly made by casting are now
fabricated by welding. In the Figure 1 below, smaller components are fabricated separately and
later welded together to form the complete assembly.

Fig. 1 Welded Parts

As a fasterner, welding usually provide greater strength at a reduction in weight compare to bolts,
rivets and others - an important advantage for moving parts of machines and transport
equipment. A common type of welding used is arc welding and gas welding. This topic
concentrate on the selection of the correct welding size for arc welding type.

Fig. 2 Arc Welding with coated electrode

Objective:
• to do stress analysis on the group of welding.
• to decide the correct size of the welding under static loading.

Scope:
• Only arc-welding is considered in this analysis.
• Fillet welding only. Butt welding is not included.
Weld M4.xmcd [Pg 2 / 8]
Sample of Welding symbols applied on work-piece

Fig. 3 FILLET WELD

(a) number indicate leg(h) size and (b) symbol indicate that the welds are intermittent
and staggered 60 mm along a 200 mm centers

Fig. 4 FILLET WELD

The circle on the weld symbol
indicates that the fillet welding
is to go all around.

Fig. 5 BUTT or GROOVE WELD

(a) square butt-welded on both sides;
(b) single V with 600 bevel and root opening of 2 mm;

FORCE AND STRESS ANALYSIS (Fillet Weld)

- DIRECT AND SHEAR LOADINGS
If load, whether direct or shear, is applied to weld, failure will occurs at the section of
smallest cross-sectional area ABCD which is called the throat area i.e along line AB
which is called the throat line.
Loads applied in welding can be categorized into Primary and Secondary Loads.
Weld M4.xmcd [Pg 3 / 8]

PRIMARY LOADS
i) Axial loads (Tensile or Compressive)
If l is the length of the weld, t is throat size, F is load applied, then in diagram below for Weld
resisting tensile load ,

F F F
σ= = =
AreaABCD A t ⋅l

F 1.414F
σ= =
0.707 ⋅ w ⋅l w ⋅l

ii) Shear loads

For diagram below, shear load is applied to the weld and the failure occurs along the line AD.
Weld M4.xmcd [Pg 4 / 8]

V V
τ= =
AreaABCD t ⋅l

V 1.414V
τ= =
0.707 ⋅w ⋅ l w ⋅l

SECONDARY LOADS
iii) Bending Load

M ⋅yi
Secondary SHEAR stress due to bending , σs =
I

iv) Torsional Load

T ⋅ ri
Secondary SHEAR stress due to twisting , τs =
J
Weld M4.xmcd [Pg 5 / 8]

Using STANDARDS (to find weld size)

The objectives of the analysis is to employ several tables and figures in specifying the length of the
legs of the fillet, the pattern of the weld and the length of the weld. The tables and figures are
provided in the standards (but only a few is shown in this book).

Allowable shear stresses and forces on welds

The allowable shear stress and force per in of leg is obtained from Table 20-3 Pg 785.

Formula for Type of Loading

P
Direct tension & compression f= Eqn 20-4
Aw

V
Direct transverse shear f= Eqn 20-5
Aw

M
Bending f= Eqn 20-6
Sw

T ⋅c
Twisting f= Eqn 20-7
Jw

Geometry Factors for weld analysis

Various formulaes for different welding patterns are shown in Fig 20-8 Pg 786.

Minimum weld sizes for thick plate

Minimum leg size for fillet weld is influenced by plate thickness. See Table 20-4 Pg 787.
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Procedure to analyze welding

1. Draw freebody diagram

2. Identify the geometry of the weld according to Figure 20-8 pg 786.

3. Identify the types of Loading/stresses to which the joint is subjected

(bending, twisting, vertical shear, direct tension or compression).

4. Analyze the joint to determine the magnitude and the direction of the force
on the weld due to each type of load.

5. Combine the forces vectorially at the point(s) of the weld where the forces
appear to be maximum.

Sample 1
Find Aw, centroid,Sw, M, Jw, T, c (if 1b) bending load (weld region E-F-G-H)
appropriate) for welding patterns 1a & 1b. (given EF=140mm, FG=200mm)

1a) twisting load

Aw = 200 + 2 ⋅( 140)
Aw = 2 ⋅( 100) 2
140
y =
100
3
+ 3 ⋅ ( 100) ⋅80
2 200 + 2( 140)
Jw =
6 2
2 ⋅( 200) ⋅( 140) + 140
Swt =
3
2
140 ⋅⎡⎣2 ⋅( 200) + 140⎤⎦
Swb =
3( 200 + 140)
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Sample 2
The bracket in (as in Sample 1b) with F = 7.5kN and horizontal distance,
L = 12cm) is shown in figure below. Determine the safety factor if leg size
w = 6mm of AWS E70 and the bracket is located in a building.

ASTM A36, A441 for building structures &

Electrode AWS E60, E70, etc

Given: force F = 7.5 ⋅ kN w = 6 ⋅mm

Distance L = 120 ⋅mm  b = 60 ⋅mm    d = 120 ⋅mm

5
Bending moment, M = F × L   M = 9 × 10 N ⋅mm

PRIMARY LOADS: Direct Vertical Shear

Geometric Factors for shear, Aw = b + 2d Aw = 300 mm

Welding length :
F N
Max force applied per mm thk fs = fs = 25
Aw mm

SECONDARY LOADS: Bending Force (secondary)

2
2b ⋅d + d 3 2
Geometric At top pt. B: Swt = Swt = 9.6 × 10 mm
Factors for 3
Bending : d ⋅( 2b + d)
2
3 2
At bot pt. A: Swb = Swb = 6.4 × 10 mm
3( b + d)

M N
Max force At top pt. B: fbt = fbt = 93.75
Swt mm
applied per
mm thk M N
At bot pt. A: fbb = fbb = 140.625 ( critical )
Swb mm

Combine both secondary and primary loads

2 2 N
The equivalent force: fe = fbb + fs fe = 142.83
mm
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Calculating allowable load (strength) of welding rod
lbf N
For E70 : Allowable force per inch of leg 11200 = 1961
in mm

N ⎞ ( w) in of leg ⎛ ( w) ⋅mm N ⎞ ( w) ⋅mm of leg

Fall = ⎛⎜ 1961
N ⎞
⎟ ⋅ = ⎜ 1961 ⎟ ⋅ = ⎛⎜ 77.2 ⎟⋅
⎝ mm ⎠ ( 1) in of leg ⎝ mm ⎠ 25.4 mm of leg ⎝ mm ⎠ mm of leg

. = ⎛⎜ 77.2
N ⎞
⎟ ⋅w
⎝ mm ⎠

Welding rod size, w = 6mm

Conclusion : Allowable Load, Fall = ⎜

⎛ 1961 ⎞ N
⎟ ⋅6 Fall = 463.228
mm
⎝ 25.4 ⎠
Fall 463.228
η= = η = 3.243
fe 142.83