MACHINE DESIGN

BML Munjal University

1 kalluri.vinayak@bml.edu.in
 Welding
• Welding is used for making permanent joints.

• A weld is defined by the American Welding society

(AWS) as “a localized fusion of materials or nonmetals
produced either by heating the materials to the required
welding temperatures with or without the application of
pressure, or by the application of pressure alone, and
with or without the use of filler materials”
 Classification of welding processes
Welding Process

Arc Gas Resistance Solid State Misc

Carbon arc Butt Friction

Metal arc Spot Ultrasonic
MIG Seam Diffusion
TIG Projection
Plasma arc Percussion Explosive
Submerged arc
Electro-slag
Thermit
Oxy-acetylene Electron-beam
Air-acetylene
Oxy-hydrogen Laser
MASTER CHART OF WELDING AND ALLIED PROCESSES
Welded Joints
SPECIFICATION OF WELD SYSTEM

The AWS standard welding symbol

ARC AND GAS WELDING SYMBOLS
 Fillet welds

(a) The number beside triangle indicates the leg size. The arrow
need to point only to one weld when the weld on all sides is
same.
(b) Here the weld symbol indicates that he weldment is
intermittent and staggered at 60 mm length at an interval of
200 mm (centre to centre distance).
 Fillet welds

Circle on the weld symbol indicates that the welding is to go

all around.
Different groove preparations for butt joints

Square butt welded on both sides. Single V with 60o bevel and root
opening of 2 mm

Double V Single bevel

Different groove preparations for fillet joints

T joint for thick plates U and J joints for thick plates

Corner weld, meant only Edge weld for sheet metal and
for light loads light loads
 Stress Analysis and Design of Welded Joints
• Butt joint
• Lap joint or Fillet joint
– Parallel fillet joint (weldment parallel to the load)
– Transverse fillet joint (weldment perpendicular to the load
direction)
• Shear welded joint
– Both primary and secondary shear stresses act
– Line weld concept is useful
• Bending welded joint
– Throat shear stress equal to 1/1.414 times the bending stress
acts.
– Line weld concept is useful
 ANALYSIS OF BUTT JOINTS
Typical butt joints with possible loading. Reinforcements, though can
increase the area taking the load, normally for fatigue loading induce
stress concentration at location like “A” and hence normally removed
by grinding or machining.

  F / hl   F / hl
Typical transverse fillet weld

Fs  F sin
Fn  F cos
t h h 2
 
sin 45 sin135   cos  sin 
o o
The stresses at any angle in the weldment are
Fs  F sin 
Fn  F cos 
t h h 2 h
   t 
sin 45o sin 135o    cos   sin   cos  sin  

Fs Fs F sin cos  sin  F sin cos  sin2  

   
A tl hl hl
Fn Fn F cos cos  sin  F cos2   sin cos 
   
A tl hl hl
The resultant von-Mises stress is

 '    3  
2 F2

hl
cos   sin cos   sin   sin cos  
2 2 2 2
The stresses at any angle in the weldment are
0
The maximum von - Mises stress occurs at 62.5 ,
2 . 16 F
 max   '   62 . 5 o 
'

hl
1 . 196 F
   62 . 5 o 
hl
0 . 623 F
   62 . 5 o 
hl
Parallel Fillet Weld: Welding Code Method

h
t
cos   sin  

For   45 0 , t  0 .707 h

  F / 0 .7 0 7 h l  1 .4 1 4 F / h l
 Problem

The figure (b=d=50mm) shows a

horizontal steel bar of thickness h = 5
mm loaded in steady tension and
welded to a vertical support. Find the
load F that will cause an allowable
shear stress is 140 MPa in the throats of
the welds.
20 kalluri.vinayak@bml.edu.in
Minimum Weld-Metal Properties

Table 9–3: page 482

Stresses Permitted by the AISC Code for Weld Metal

Table 9–4: page 482

SHEAR WELDED JOINT

a
 SHEAR WELDED JOINT
Primary shear stress:
 V / A
Secondary shear stress:

Twisting moment:
T = Fa a

J  Second polar moment of area of the weldments

about the cetroid of the weldment areas
  J Gi   I
 A i ri 2  xx  I yy   Ar 
i i i
2
An example of unequal weldments
b1  0.707 h1
d 2  0.707 h2
h1  leg size of weldment - 1
h2  leg size of weldment - 2
The total throat area against primary
shear
A A  A t d t b
1 2 1 2
Secondary shear estimation needs the estimation of the total
second polar moment of area of the two weldments together.
t1 d 3 dt 13 t1 d 3 dt 13
I x 1  ; I y 1  ; J G1  I x 1  I y 1  
12 12 12 12
bt 23 t 2b 3 bt 23 t 2 b 3
I x 2  ; I y 2  ; J G 2  I x 2  I y 2  
12 12 12 12
An example of unequal weldments
The centroid G can be
located as follows.
A1 x1  A2 x2
x
A
A1 y1  A2 y2
y
A

r1  x  x 1 
2
 y 2
; r2  x 2  x   y 2  y 
2 2

  
J  J G 1  A1 r12  J G 2  A 2 r22 
 The concept of line weldments
J  0.707hJ u
J u  Second polar moment of area for unit weld throat size

G d x 0
A  0.707 hd J u  d 3 / 12
y  d /2

The different patterns and their properties are listed in

Table 9-1.
Torsional Properties of Fillet Welds

J  0.707hJ u

(Table 9-1, page:476)

Few torsion cases and equivalent line weldment diagrams

Note: check the orientation

Problem
A torque T=2 kN-m is applied to the weldment as shown.
Estimate the maximum shear stress in the weld.
Problem
A 20 mm thick steel bar is welded to a vertical support by
two fillet welds. Find the safe force F if the permissible
shear stress in the welds is 180 MPa.
Problem
A 20 mm thick steel bar is welded to a vertical support by
two fillet welds is shown in Fig. Find the safe bending force
F if the electrode is E7010, bar is HR 1020, and the support
is HR 1015.
 BENDING WELDED JOINT

V
Primary shear stress,  ' 
A
 BENDING WELDED JOINT-Contd.
Secondary shear stress: A throat shear of  is induced. where 
is the bending stress calculated by the following formula. In deriving
the formula the weldments have been treated as line welds and also the
distance between them is treated as simply equal to d, which is the
depth of the rectangular pattern.
bd 2
Iu 
2
bd 2
I  0.707hI u  0.707 h
2
Mc Md / 2 1.414 M
  2

I 0.707hbd / 2 bdh
Bending Properties of Fillet Welds

I  0.707hI u

(Table 9-2; page:480-481)

Bending Properties of Fillet Welds - contd….

(Table 9-2; page:480-481)

Few bending cases and equivalent line weldment diagrams
Find the maximum shear stress in the throat of the
weld metal in the figure

38 kalluri.vinayak@bml.edu.in
case (2) of table 9  2 :
h  10 mm; d  200 mm; b  25 mm
A  2(0.707)(10)(200)  2828 mm 2
d 3 200 3
Iu   1.33  10 6 mm 3
6 6
I  0.707 h I u  0.707  10  1.33  10 6  9.43  10 6 mm 4
F 20  1000
'    7.07 MPa
A 2828
M  20000  150  3  10 6 N  mm
d
c  100 mm
2
M c 3  10 6  100
 
''
  31.8 MPa
I 9.43  10 6

 max      
' 2 '' 2
 7.07 2  31.82  32.58 MPa
39 kalluri.vinayak@bml.edu.in
Problem
The Fig shows a welded steel bracket loaded by a static
force. Find the factor of safety if the allowable shear stress
in the weld throat is 120 MPa.
Problem

41 kalluri.vinayak@bml.edu.in
42 kalluri.vinayak@bml.edu.in
43 kalluri.vinayak@bml.edu.in
Welded Joint under Fatigue loading
The conventional methods will be used
 In fatigue, the Gerber criterion is best; however, you
will find that the Goodman criterion is in common use.
For the surface factor, forged surface should always be
assumed for weldments unless a superior finish is
specified and obtained.
Fatigue Stress-Concentration Factors, Kfs

Table 9–5
Problem
The weldment shown in the figure (b=d=50 mm) is subjected to
an alternating force F. The hot-rolled steel bar has a thickness
h=5 mm and is of AISI 1010 steel. The vertical support is
likewise AISI 1010 HR steel. The electrode is E6010. Estimate
the fatigue load F the bar will carry if three fillet welds are used.
Problem
The weldment is subjected to a completely reversed force
F. The hot rolled steel bar is 10 mm thick and is of AISI 1010
steel. The vertical support is of AISI 1010 steel. The
electrode is 6010 with fully corrected endurance strength
of 80 MPa. Estimate the completely reversed load F the bar
will carry.