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welds
• Jim Wong
– WongJamesD@JohnDeere.com
– 309-765-3891
Global Loads
Material Properties
Local Loads, Stresses or Strains
Stress concentration Factors
Peak stress at weld toe/critical points
Through thickness stress distribution
Residual Stresses
peak
n
nom
peak
D
r E
hs
h
p
n
M
h P
B
t
A
C
H
t
C
tp
r
V
n peak n
H
t
C
x
t
0.4t Strain
Courtesy: E. Niemi
1.0t gauges
n2
b1
2)
y
b2 =n2
2pe
ak
x
t
b
2
b) y
b) Pure bending
hs b
bpeak load
M
x
t
b
c) d
)
h
s
Independent of L but it
changes along the weld toe
line
a) Stress distribution in the critical cross section near the cover plate ending
and the nominal or the hot spot stress n (independent of length L ) and hs
(independent of length L),
b) Stress distribution in the critical plane near the ending of a vertical
attachment (gusset) and the nominal or the hot spot stress n (dependent on
length L ) or hs (independent of length L)
© 2008 Grzegorz Glinka. All rights reserved. 17
The advantage of using expression
lies in the fact that the membrane stress hsm and the bending
stress hsb can be determined by simple decomposition of the
linearized through-thickness stress field, (x=0,y), which can be
directly obtained from the coarse mesh 3-D or shell Finite
Element (GY2) analysis. Thus the equation above provides the
link between the FE stress analysis data, hsm and hsb, and the
peak stress, peak, at the weld toe, necessary for the fatigue
analysis
a) c)
tp
hp physical common plane
middle plane for the attachment and
of the main the main plate
plate
h
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t image may have been corrupted. Restart your computer, and then open the file again. If the red x still
appears, you may have to delete the image and then insert it again.
y
x
y d) 0
b) h
z
x
0
z
h/2
(h+t/2)
h/2
h/2
(h/2+tp/2) h/2 h/2 h/2
(h/2+t/2)
(h+tp/2)
tp h
e
i
m
a
g
e
c
h physical common
middle plane of a
n
n plane for the
the main plate o
t
b
e attachment and the
d
h i
s
main plate
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t corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and
then insert it again.
Element Nodes
h
Reference points where
stress is to be determined h/2
(h+t/2)
h/2
h/2
(h/2+t/2)
(h+tp/2)
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image, or the image may have been corrupted. Restart your computer, and then open the file
again. If the red x still appears, you may have to delete the image and then insert it again. t
main plate
middle plane
(tp/2 + t/2)
t/2
t/2
h/2 t/2 t/2
Shell FE model
top
Shell element at midplane
bottom
Run Smart, Run Fast, Run Lean 25
6 mm
Global loads
Material Properties
Local loads, stresses or strains
Stress concentration factors
Peak stress at weld toe/critical points
Through thickness stress distribution
Residual stresses
g=h
t
P P
Range of application - reasonably designed weldments, (K.Iida and T. Uemura, ref. 11)
g=h
t
M M
Range of application - reasonably well designed weldments, (K.Iida and T. Uemura, ref. 11)
h
x
P P
t
y
h
x
M
M
t
y
where:
0.04
MF-5 MF-1
0.03
f()
MF-4 MF-3
0.02
MF-2
MF-1: μ=4.0789, =0.1710
MF-2: μ=3.7854, =0.4668
MF-3: μ=3.9496, =0.2665
0.01
MF-4: μ=3.9669, =0.4135
MF-5: μ=4.0084, =0.2832
0.0
0.0 40.0 80.0 120.0 160.0 200.0
Angle, [deg]
0.96
MF-3
0.72 MF-5
MF-4
f(Ktt)
MF-1
0.48
0.00
0.0 1.8 3.6 5.4 7.2 9.0
SCF, (Ktt)
MF-3
0.64
MF-5
MF-4
MF-1
0.48
f(Ktb)
MF-2
0.32
MF-1:
MF-2:
MF-3:
0.16 MF-4:
MF-5:
0.00
0.0 2.0 4.0 6.0 8.0
SCF, (Ktb)
0.90
MQ2 – production line 0.80
Probability
0.30
0.25
0.20
0.15
0.10
0.08
0.06
0.04
0.02
0.01
0.1 0.2 0.4 0.7 1 2 4 7 1
0
Weld toe radius, r
[mm]
© 2008 Grzegorz Glinka. All rights reserved. 38
Weld Life Check List
Global loads
Material properties
Local loads, stresses or strains
Stress concentration factors
Peak stress at weld toe/critical points
Through thickness stress distribution
Residual stresses
Derived
for:
© 2008 Grzegorz Glinka. All rights reserved. 40
Where:
Derived for:
Global Loads
Material Properties
Local Loads, Stresses or Strains
Stress concentration Factors
Peak stress at weld toe/critical points
Through thickness stress distribution
Residual Stresses
The residual stress can not be added linearly to the actual stresses at the
notch tip. However, the residual stress effect can be accounted for by adding
it to the pseudo-elastic stress in the Neuber formula.
Global Loads
Material Properties
Local Loads, Stresses or Strains
Stress concentration Factors
Peak stress at weld toe/critical points
Through thickness stress distribution
Residual Stresses
=tp hp
t
y
19,197 nodes
18,858 elements
114,069 dof
Material:
A22H Steel (ASTM A500 Cold Formed
Steel for Structural Tubing)
885,069 nodes
613,891 elements
2,700,000 dof
60
T-Joint experimental vs predicted life
61
Gusset Weld
62
Gusset – Out of Plane Loading
63
Gusset –In Plane Loading
64
Square tube on plate
65
Square tube on plate
Fig. 41. Calculated total fatigue live based on the GY2 hot spot stress approach and the experimental fatigue data
using the JD material data; Welded tube-on-plate specimen (fully reversed lateral load of 21350 N)
66
Weld Life Check List
Global Loads
Material Properties
Local Loads, Stresses or Strains
Stress concentration Factors
Peak stress at weld toe/critical points
Through thickness stress distribution
Residual Stresses
Structural Analysis