Machine Design

3/18/2018
Ch # 9
Permanent Joints
ME-305 (Machine Design II)

– Welding
– Brazing
– Soldering
– Cementing
– Gluing
• Welding is widely used in fabrication
• As a replacement for bolted and riveted joints
• Use for repairing
Types of Welding
• Electric Arc welding

– Shielded Metal Arc (SMAW) or Stick

– Metal Inert Gas (MIG)
– Tungsten Inert Gas (TIG)
– Flux-cored Arc (FCAW)
– etc.
• Gas welding
– Oxy-Acetylene
– Oxy-Gasoline
– Butane-Propane
– etc.
• Thermit welding
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Types of Welded Joints
1. Lap or Fillet

2. Butt
9-1 Welding Symbols
• The most common

• Representation on manufacturing drawings
Length
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3
ME-305 (Machine Design II) ME-305 (Machine Design II)
9-1 Welding Symbols…
9-1 Welding Symbols…

3/18/2018
9-2 Butt and Fillet Welds
• The Normal Stress in the Butt joint

due to tension or compression loading
→ 9.1
• The average Shear Stress in the Butt
joint
→ 9.2
• h is the throat length
9-2 Butt and Fillet Welds…
• The Shear Stress in Transverse

Fillet Weld is
→ 1
• The Normal Stress in the
Transvers Fillet Weld is
→ 2
• Where
• t is the throat thickness
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• t is calculated using sines law

45 180 45
2
135
• From which
sin
• Put for Fs and t in (1) to get
→
• Put for Fn and t in (2) to get
→
sin(A − B) = sin A cos B − cos A sin B
• The von Mises stress at angle  is

• It is found that the largest von Mises stress

occurs at an angle 62.5o. Then
1.196
0.623
σ
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• The Shear Stress in Parallel Fillet

Weld is (only shear stress occurs)
1.414
→ 9.3
9-3 Stresses in Welded Joints in Torsion
• Locate the critical point(s) and label

• Calculate primary shear (A is throat area)

→ 9.1
• Calculate the secondary shear or torsion
→ 9.1
• r is the distance from the centroid of the
weld group.
• Centroid ̅ and can be determined using
Table 9-1
• And J = 0.707hJu
• Ju is taken from Table 9-1
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9-3 Stresses in Welded Joints in Torsion…
Example 9-1
• A 50-kN load is
transferred from a
welded fitting into a
200-mm steel channel
as illustrated in
Figure. Estimate the
maximum stress in the
weld.
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Example 9-1 (Solution)

a) Label the ends and corners

of each weld by letter
b) Estimate the primary shear
,
c) Locate the centroid of the

weld pattern ̅
d) Find distances
e) Find J using Table 9-1
f) Find M
g) Find secondary shear ,,
h) Find  (angle of ,, along ̅ )
i) Find Shear stresses at all
ends and corners
j) Identify the most stress point
9-4 Stresses in Welded Joints in Bending
• Figure shows a welded joint

subject to eccentric loading

• The eccentric load produces a
vertical primary stress as
→
• and a horizontal bending
stress as
→
• Where and 0.707

• Iu is taken from Table 9.2
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9-4 Stresses in Welded Joints in Bending…
• The vertical and

horizontal stress
components are vector
sum to give the total weld
stress
- Welding Electrode Classification

• Also known as Filler rod
• Represented on drawing as 
• Written as Exxxx-X, (E7018-X)
• E Indicates that this is an electrode
• 70 Indicates how strong this electrode is
when welded, measured in thousands of psi.
• 1 Indicates in what welding positions it can be used.
• 8 Indicates the coating, penetration, and current
type used. (See Weld Classification Table)
• X Indicates that there are more requirements. (See
Additional Requirements of weld)
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- Welding Electrode Classification…

• Welding positions

1. Flat, Horizontal, Vertical (up), Overhead
2. Flat, Horizontal
3. Flat, Horizontal, Overhead, Vertical (down)
9-5 The Strength of the Welded Joints
• Welding Electrode properties

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9-5 The Strength of the Welded Joints…
• Minimum fillet weld sizes

Table 9-6 comes here
9-6 Static Loading

Example 9-2
• A 12-mm by 50-mm rectangular-cross-section

1015 bar carries a static load of 73 kN. It is welded
to a gusset plate with a 10-mm fillet weld 50-mm
long on both sides with an E70XX electrode as
depicted in Fig. Use the welding code method.
a) Is the weld metal strength satisfactory?
b) Is the attachment strength satisfactory?
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9-6 Static Loading…
Example 9-2 (Soln.)

a) Weld metal Strength
• From Table 9-6, allowable force per unit length for a
10mm, E70 electrode is 1025 N/mm of weldment; thus
1025 1025 50 50 102.5 kN
• Since 102.5 > 73 kN, weld metal is Satisfactory.
b) Attachment Strength (in Shear) Should not exceed

0.40Sy of base metal.
• Sy = 190 MPa (Table A-20), and
• 0.4 0.4 190 76 MPa (Table 9-4)
• The shear stress on the base metal adjacent to the weld
is;
73 MPa
. .
Example 9-2 (Soln.)…

• Since i.e. 76 >73 MPa, the attachment is

Satisfactory in “shear” near the weldment.
b) Attachment Strength (in Tension)

• Sy = 190 MPa (Table A-20), and
• 0.6 0.6 190 114 MPa (Table 9-4)
• The tensile stress on the shank of the attachment is;
. .
122 Mpa
• Since i.e. 114 < 122 MPa, the attachment is
Unsatisfactory in “tension” at the shank.
• By changing thickness of the bar from 12 mm to 13 mm will
make it Satisfactory.
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Example 9-4

• Perform an adequacy assessment (by
calculating the f.o.s) of the statically
loaded welded cantilever carrying
2.2kN. The cantilever is made of AISI
1018HR steel and welded with a 10-
mm fillet weld as shown in the figure.
An E6010 electrode was used, and
the design factor was 3.0.
a) Use the conventional method for the
weld metal.
b) Use the conventional method for
the attachment (cantilever) metal.
c) Use a welding code for the weld
metal.
Example 9-4 (soln.)

(a) Adequacy of the Weldment

• The weld pattern is “Fillet” and under “Bending”. From
Table 9-2,
1.41 1.41 10 50 707 mm2
20833 mm3
0.707 0.707 10 20833 147289 mm4
• From Table 9-3, for E6010,
345 MPa, 427 MPa
• Primary shear
3.1 MPa
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Example 9-4 (soln.)…

• Secondary shear
56 MPa
• The shear stress is
⁄
56.1 MPa
• Factor of Safety
0.577 0.577 345
3.55
56.1
• Since i.e. 3.55 3.0, the weld metal is
“Adequate”.

(b) Adequacy of the Attachments

• Bending stress in the attachment
⁄
79.2 MPa
• From Table A-20, for 1018 HR steel, 220 Mpa

• Factor of Safety
220
2.78
79.2
• Since i.e. 2.78 3.0, the attachment is “Not
adequate”.
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(c) Adequacy of the Weldment (using Welding Code)
• From part (a)
56.1 Mpa
• From Table 9-6, Allowable shear stress on the throat of
E6010 fillet weld is 124 MPa, then
124
2.2 → i
56.1
• But is calculated using DE theory and already
includes a fos which is
0.577 0.577 345
1.6 → ii
124
• The factor of Safety will be (i) multiply by (ii)
2.2 1.6 3.53 [Adequate]
9-7 Fatigue Loading
Example 9-6
• The 1018 steel strap of Figure has a repeatedly

applied load of 9 kN (Fa = Fm = 4.5 kN). Determine
the fatigue factor of safety of the weldment using
Gerber fatigue failure criterion.
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9-7 Fatigue Loading…
Example 9-6 (Soln.)

• 1 1
Where
• 0.67
•
• 2 0.707
•
• 0.5
5.99
Problems
• 9-2, 3, 8, 9, 14, 17, 20, 22, 26, 35, 45, 52
From
Shigley’s Mechanical Engineering Design, 9th Ed.
16

Machine Design

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3/18/2018

ME-305 (Machine Design II)

• Electric Arc welding

– Shielded Metal Arc (SMAW) or Stick

Types of Welded Joints

ME-305 (Machine Design II)

9-1 Welding Symbols

• The most common

• Representation on manufacturing drawings

9-1 Welding Symbols…

9-2 Butt and Fillet Welds

• The Normal Stress in the Butt joint

ME-305 (Machine Design II)

9-2 Butt and Fillet Welds…

• The Shear Stress in Transverse

• t is the throat thickness

9-2 Butt and Fillet Welds…

ME-305 (Machine Design II)

9-2 Butt and Fillet Welds…

• The von Mises stress at angle  is

• It is found that the largest von Mises stress

9-2 Butt and Fillet Welds…

• The Shear Stress in Parallel Fillet

ME-305 (Machine Design II)

9-3 Stresses in Welded Joints in Torsion

• Locate the critical point(s) and label

• Calculate primary shear (A is throat area)

9-3 Stresses in Welded Joints in Torsion…

ME-305 (Machine Design II)

Example 9-1 (Solution)

ME-305 (Machine Design II)

c) Locate the centroid of the

9-4 Stresses in Welded Joints in Bending

• Figure shows a welded joint

subject to eccentric loading

• Where and 0.707

9-4 Stresses in Welded Joints in Bending…

• The vertical and

ME-305 (Machine Design II)

- Welding Electrode Classification

- Welding Electrode Classification…

ME-305 (Machine Design II)

9-5 The Strength of the Welded Joints

• Welding Electrode properties

9-5 The Strength of the Welded Joints…

• Minimum fillet weld sizes

ME-305 (Machine Design II)

9-6 Static Loading

• A 12-mm by 50-mm rectangular-cross-section

9-6 Static Loading…

Example 9-2 (Soln.)

ME-305 (Machine Design II)

b) Attachment Strength (in Shear) Should not exceed

9-6 Static Loading…

Example 9-2 (Soln.)…

• Since i.e. 76 >73 MPa, the attachment is

b) Attachment Strength (in Tension)

9-6 Static Loading…

ME-305 (Machine Design II)

9-6 Static Loading…

Example 9-4 (soln.)

(a) Adequacy of the Weldment

9-6 Static Loading…