BASIC OF WELD DESIGN Chapter 3.
04
FUSION WELDED JOINT
FORCE FLOW & STRESS PROFILE : BUTT WELD
The applying force-flows and the associated stresses can be represented more simplified by lines of forces
FORCE FLOW & STRESS PROFILE :
DOUBLE FILLET WELD
WELD STRESSES
AXIAL STRESS :
PARALLEL TO LONGITUDINAL DIRECTION OF THE WELD
Does not have to be taken into
consideration primarily for statically
loaded construction
AXIAL STRESS : PERPENDICULAR TO THE
LONGITUDINAL DIRECTION OF THE WELD
Does often not require mathematical
evidence if the specified minimum
yield- and tensile strength of the weld
metal is not less than those of the base
material
AXIAL STRESS : PERPENDICULAR TO THE
LONGITUDINAL DIRECTION OF THE WELD
Weld-stress appears perpendicular to
the weld direction and has to be
calculated
SHEARING STRESS : PARALLEL TO THE
LONGITUDINAL DIRECTION OF THE WELD
The weld stress appears in the plane of
the throat parallel to the axis of the
weld under combined shear
stress/bending stress
HAVE TO BE CALCULATED
SHEARING STRESS : PERPENDICULAR TO THE
LONGITUDINAL DIRECTION OF THE WELD
The weld stress appears in the plane of
the throat perpendicular to the axis of
the weld
HAVE TO BE CALCULATED
EXAMPLE
WELD DIMENSION
WELD THICKNESS
WELD THICKNESS : FULL PENETRATION
Full Penetration Butt Weld
a weld with full penetration and
complete fusion of the weld material
with the base material over the
thickness of the connection
WELD THICKNESS : PARTIAL PENETRATION
The weld size is less than the base material thickness
Intermittent butt welds are to be avoided
A version with cyclic loading of components should be avoided
WELD THICKNESS : FILLET
The calculated size a of a fillet weld s is equal to the measured height from the
theoretical root point of the inscribed isosceles or non-isosceles triangle
WELD THICKNESS : FILLET (DEEP PENETRATION)
An enlarge weld size a must be taken into account in the calculation when penetration
beyond the theoretical root point e
This is only applicable for partially and fully mechanized welding
TYPE OF FILLET WELDS
The throat thickness of fillet welds should be generally taken out of the static calculation
and be specified in the technical documentation (Shop drawing)
WELD LENGTH
BUTT LENGTH
Weld length =
The total length of a weld or the width
of the welded component Iw,eff
These plates must professionally be removed
after weld completion either mechanically, by
burning or by plasma cutting followed by
grinding of the specific area
FILLET WELD
The effective length = total length of the root line when it is fully executed, including the weld crater ends.
If it is not fully executed, a reduction of the effective length must be made
FILLET WELD
Minimum weld length for allowing any load at all as for the maximum weld lengths without any conditions
FILLET WELD
The unconditioned maximum weld limit is due to the non-uniform stress distribution over the connection length.
With the increasing weld lengths higher stress concentrations are being initiated at the both ends of the weld
length in comparison with the calculated stress
CROSS-SECTION PROPERTIES
OF A WELD
BUTT AND FILLET WELDS
MOMENT OF INERTIA (2 ND MOMENT OF AREA)
STATIC MOMENT (1 ST MOMENT OF AREA)
FORMULA FOR STRESS CALCULATION
IN WELD JOINTS
EXAMPLE 01
EXAMPLE 02
EXAMPLE 03
EXAMPLE 04
EXAMPLE 05
EXAMPLE 06
WELD STRESS DUE TO LONGITUDINAL OR
TRANSVERSE DIRECTED FORCES
WELD STRESS DUE TO BENDING MOMENT
WELD STRESS DUE TO SHEAR FORCE
COMPARISON VALUE (DESIGN WELD RESISTANCE)
Similar stress types in weld joints can be calculated by linear superposition of the separate stress
components, taking into account the sign
EXAMPLE
LOAD CAPACITY
The load capacity depends on the strength of the base materials of the connected
components.
It must be ensured that values for yield strength, tensile strength, elongation at break
and impact energy specified of the weld metal are least equal to the values of the
base material to be welded.
Professionally manufactured → welding consumables and base materials can be
considered to be equivalent.
Indication of the quality of welding fabrication → non-destructive test (visual
inspection, radiographic or ultrasonic examination.
The load capacity of a welded joint is dependent on their quality
QUALITY LEVELS OF IMPERFECTION (ISO 13919)
The load capacity is stated differently in different sets of rules and depends also on whether
predominantly static or cyclic loading is present
ALLOWABLE STRESS
ALLOWABLE STRESS FOR WELDED JOINTS WITH
STATIC LOADING
EXERCISE 01
EXERCISE 02
EXERCISE 03
COMMON TORSIONAL PROPERTIES OF FILLET WELDS
(TABLE 9–1)
SHIGLEY’S MECHANICAL ENGINEERING DESIGN
COMMON TORSIONAL PROPERTIES OF FILLET WELDS
(TABLE 9–1)
SHIGLEY’S MECHANICAL ENGINEERING DESIGN
BENDING PROPERTIES OF FILLET WELDS (TABLE 9–2)
SHIGLEY’S MECHANICAL ENGINEERING DESIGN
BENDING PROPERTIES OF FILLET WELDS (TABLE 9–2)
SHIGLEY’S MECHANICAL ENGINEERING DESIGN
EXERCISE 02
CENTER OF GRAVITY AND CROSS-SECTION AREA
SECOND MOMENT OF INERTIA
NORMAL STRESS (UPPER SURFACE)
NORMAL STRESS (LOWER SURFACE)
STATIC MOMENT (UPPER AREA)
STATIC MOMENT (LOWER AREA)
SHEAR STRESS (UPPER AREA)
SHEAR STRESS (LOWER AREA)
RESISTANCE SPOT WELDING
GEOMETRICAL ARRANGEMENT
CENTER DISTANCE
DESIGN MARGIN, THE DISPLACEMENT ANF THE
LENGTH OF OVERLAP
STRUCTURAL DESIGN
Good accessibility for welding electrodes at the weld
Flat parallel bearing surface
Avoid multiple shear connections with more than 4 sheets
Arrange thinner sheets as possible between the thicker
Avoid sheet thickness differences > 3:1
LOAD
The concentrated forces are transmitted locally
Preferable to be subjected to shear load.
Pure head-. Peeling-, and torsional loads are to
be avoided by design measures
LOAD
QUALITY FACTOR Q (DVS EN 10130)
METHOD FACTOR V (DVS EN 10130)
WELD STRESS RESISTANCE :
STATICAL SHEAR LOAD
SAFETY FACTOR S (DVS EN 10130)
MINIMUM SHEAR FORCE
(F MIN ) AND MINIMAL
YIELD FORCE (F S MIN )
STATIC HEAD LOAD CAPACITY
STATIC PEEL-LOAD CAPACITY
CYCLIC LOAD CAPACITY
