Machine Design

Tutorials
Spring/Summer 2020
July 9th - Week 10
DGD 9
Problem 1
The two 7-mm thick plates (𝑆𝑦 = 350 MPa) are welded together by
convex fillet welds along sides AB and CD. Each weld metal has a yield
strength of 350 MPa. Use a 5-mm weld leg and safety factor of 3 to
estimate the static load F that can be carried by the joint shown in the
figure, based on yielding.

7 𝑚𝑚

7 𝑚𝑚
𝑆𝑦 = 350 𝑀𝑃𝑎 (𝑝𝑙𝑎𝑡𝑒)
ℎ = 5𝑚𝑚
𝑆𝐹 = 3
Assumptions
1. The plates themselves do not fail; shear failure occurs in the weld throat area

2. The throat length is given by t=0.707h (convex weld bead)

Fig. 11.7 a in J&M

3. The weld efficiency is 100% (see section 11.4 pg 478, paragraph 5)

Weld throat length:

𝑡 = 0.707 5𝑚𝑚 = 3.535 𝑚𝑚

Weld throat area (both welds):

𝐴 = 𝑡 × 50𝑚𝑚 × 2 𝑠𝑖𝑑𝑒𝑠 7 𝑚𝑚

𝐴 = 3.535𝑚𝑚 50𝑚𝑚 2 = 353.5𝑚𝑚2 7 𝑚𝑚

Weld throat area is stressed in shear:

For steel, yield strength in shear: 𝑆𝑠𝑦 = 0.58𝑆𝑦 = 203 𝑀𝑃𝑎

Applied force required:

𝐹
𝑆𝑠𝑦 = 𝑆𝐹
𝐴
𝑆𝑠𝑦 𝐴 203𝑀𝑃𝑎 353.5𝑚𝑚2
𝐹= = = 23,920 𝑁 = 23.9 𝑘𝑁
𝑆𝐹 3 𝐴𝑁𝑆.

7 𝑚𝑚
Comment: If the top plate has a x-sectional area of
𝐴 = 40 7 = 280 𝑚𝑚2 , the load capacity would 7 𝑚𝑚

be 𝐹 = 𝑆𝑦 𝐴 = 350 280 = 98𝑘𝑁. → Significantly

exceeds that of the weld ie. assumption that the
plate would not fail was valid
Problem 2
(Open ended design problem: the solution is not unique)

Select two steel plates with 𝑆𝑦 = 50 ksi that can be attached by 3/8” parallel-loaded
fillet welds and design an assembly that can transmit a load greater than 14,000 lb.
Decisions: Schematic and Given Data:
1. Select two plates at least 3/8" in thickness.
2. Employ a safety factor of 3.
3. Use E60 series welding rods. 𝐴 𝐷
4. Use a weld length of 3” (6” in total).

𝐵 𝐶
Assumptions:
1. The throat length is given by 𝑡 = 0.707ℎ.
2. The weld efficiency is 100%.
E60 Welding rods
3. The steel plates do not fail in tension. 𝑆𝑦 = 50 ksi
ℎ = 3/8" = 0.375 𝑖𝑛.
SF = 3
Throat Area: Shear Yield Strength:
𝐴 = 0.707ℎ ∗ 𝐿 𝑆𝑠𝑦 = 0.58𝑆𝑦
3
𝐴 = 0.707 6 = 1.59 𝑖𝑛2 𝑆𝑠𝑦 = 0.58 48 = 27.8 𝑘𝑠𝑖
8

Weld Material (E60) Yield Strength: Maximum Tensile Load:

From Section 11.4 of J&M Txtbk, pg 478 paragraph 4: 𝑆𝑠𝑦 𝐴
𝐹=
“Specified yield strengths for E60 and E70 series welding 𝑆𝐹
rods are about 12 ksi below the tensile strengths”
(27800 𝑝𝑠𝑖)(1.59 𝑖𝑛2 )
=
3
𝑆𝑦 = 60 − 12 = 48 𝑘𝑠𝑖
= 14 700 𝑙𝑏 > 14 000 𝑙𝑏
Problem 3
A part welded using an E60 welding rod has out-of-plane eccentric
loading (see figure). The safety factor is 3. Determine the weld size
required if only the top of the joint is welded.
*(This problem is an extension of Sample Problem 11.4D in Juvinall and Marshek Textbook).

E60 series welding rod

S𝑦 = 345 𝑀𝑃𝑎

𝑆𝐹 = 3

Force applied at midpoint

of cylindrical hole
Assumptions:

1. The direct shear stresses are uniformly distributed over the length of all welds.
2. The parts being joined are completely rigid.
3. The throat length is 𝑡 = 0.707ℎ.

Fig. 11.7 a in J&M

 Moment of inertia about neutral bending axis X-X:
Analysis 1: (two welds)
𝐼𝑋 = 𝐼𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑤𝑒𝑙𝑑𝑠 + 𝐼ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑤𝑒𝑙𝑑𝑠
Assume: The absence of weld CD will not
Since we have no vertical welds and two horizontal welds,
alter the bending stresses. So, we solve the
problem as if there is a weld at AB and CD. 𝐼𝑋 ≈ 2𝐼ℎ = 2(Lta2 )
= 2 70 𝑡(60)2 = (504 000)t

Bending stress on welds:

𝑀𝑐 10 000 160 (60) 190.5
σ= = = MPa
𝐼 504 000 𝑡 𝑡

Transverse stress on welds:

𝑉 10 000 71.4
𝜏= = = MPa
𝐴 2(70)𝑡 𝑡

Resultant stress:
1 2 2
1 2 2
203
𝜏𝑅 = 𝜏 +σ = 190.5 + 71.4 = MPa
𝑡 𝑡 𝑡
 Using the distortion-energy (DE) theory:
Analysis 1: (two welds)
𝑆𝑦𝑠 = 0.58𝑆𝑦 = 0.58 345 = 200.1 𝑀𝑃𝑎
Assume: The absence of weld CD will not
alter the bending stresses. So, we solve the Convention is to regard the resultant stress as a shear stress
acting in the plane of the weld throat and to equate it to the
problem as if there is a weld at AB and CD. allowable shear stress.

𝑆𝑦𝑠 203 200.1

𝜏𝑅 = → = → 𝑡 = 3.04𝑚𝑚
𝑆𝐹 𝑡 3

Solving for weld leg length h:

𝑡 = 0.707ℎ

3.04𝑚𝑚
→ ℎ= = 4.30𝑚𝑚
0.707
 Moment of inertia about neutral bending axis X-X:
Analysis 2: (one weld)
𝐼𝑋 ≈ 𝐼ℎ = Lta2
Assume: The weld at CD is absent = 70 𝑡(60)2 = (252 000)t
and bending occurs at axis X-X.
Bending stress on weld AB:
𝑀𝑐 10 000 160 (60) 380.9
σ= = = MPa
𝐼 252 000 𝑡 𝑡

Transverse stress on weld AB:

𝑉 10 000 142.9
𝜏= = = MPa
𝐴 (70)𝑡 𝑡

Resultant stress:
1 2 2
1 2 2
406.8
𝜏𝑅 = 𝜏 +σ = 380.9 + 142.9 = MPa
𝑡 𝑡 𝑡
 Using the distortion-energy (DE) theory:
Analysis 2: (one weld)
𝑆𝑦𝑠 = 200.1 𝑀𝑃𝑎
Assume: The weld at CD is absent
and bending occurs at axis X-X. 𝑆𝑦𝑠 406.8 200.1
𝜏𝑅 = → = → 𝑡 = 6.1 𝑚𝑚
𝑆𝐹 𝑡 3

Solving for weld leg length h:

𝑡 = 0.707ℎ

6.1 𝑚𝑚
→ ℎ= = 8.63 𝑚𝑚
0.707
 Moment of inertia about neutral bending axis X-X:
Analysis 3: (rotation about CD)
𝐼𝑋 ≈ 𝐼ℎ = Lta2
Assume: Bending occurs at CD = 70 𝑡(120)2 = (1 008 000)t
rather than at axis X-X.
Bending stress on weld AB:
𝑀𝑐 10 000 160 (120) 190.5
σ= = = MPa
𝐼 1 008 000 𝑡 𝑡

Transverse stress on weld AB:

𝑉 10 000 142.9
𝜏= = = MPa
𝐴 (70)𝑡 𝑡

Resultant stress:
1 2 2
1 2 2
238
𝜏𝑅 = 𝜏 +σ = 190.5 + 142.9 = MPa
𝑡 𝑡 𝑡
 Using the distortion-energy (DE) theory:
Analysis 3: (rotation about CD)
𝑆𝑦𝑠 = 200.1 𝑀𝑃𝑎
Assume: Bending occurs at CD
rather than at axis X-X. 𝑆𝑦𝑠 238 200.1
𝜏𝑅 = → = → 𝑡 = 3.57 𝑚𝑚
𝑆𝐹 𝑡 3

Solving for weld leg length h:

𝑡 = 0.707ℎ

3.57 𝑚𝑚
→ ℎ= = 5.05 𝑚𝑚
0.707
 Analysis 1: Analysis 2: Analysis 3:
• Two welds (AB and CD) • One weld (AB) • One weld (AB)
• Bending at X-X • Bending at X-X • Bending at CD

ℎ = 4.30 𝑚𝑚 ℎ = 8.63 𝑚𝑚 ℎ = 5.05 𝑚𝑚

• When dealing with one weld, it is less conservative to assume that the bending occurs at CD. However, in
practice, bending would most probably take place closer to CD than to X-X.

• Overall, we select the highest weld size. ℎ = 8.63 𝑚𝑚

𝐴𝑁𝑆.
Problem 4
The bracket shown in the figure is to support a total load (equally
divided between the two sides) of 60 kN. Using E60 series welding
rod and a safety factor of 3, what size weld should be
specified/used?

*See sample problem 11.3D in J&M

textbook for a similar example
Assumptions
1. The direct (transverse) shear stresses are uniformly distributed over the
length of all welds

2. The parts being joined are completely rigid

3. The throat length is given by t=0.707h (convex weld bead)

Fig. 11.7 a in J&M

Basic steps
1. Find centroid of weld group
2. Relocate applied load using an equivalent force couple system
3. Find primary shear stress (translational component)
4. Find secondary shear stress (rotating component)
5. Combine primary and secondary shear stress by computing a
resultant and determine the worst-case location
6. Shear stress will be in terms of t,
𝑆𝑦𝑠
Determine t, by using 𝜏 =
𝑆𝐹
𝑡
7. Find h by solving ℎ =
0.707

Joint is symmetrical about loading,

so will use one side for analysis
Find the Centroid of the Weld Group
= 𝑤𝑒𝑙𝑑𝑠
σ 𝐴𝑖 𝑥𝑖 𝐴𝐴𝐶 𝑥𝐴𝐶 + 𝐴𝐴𝐵 𝑥𝐴𝐵 + 𝐴𝐶𝐷 𝑥𝐶𝐷
𝑥ҧ = =
75 𝑚𝑚 σ𝐴 𝐴𝐴𝐶 + 𝐴𝐴𝐵 + 𝐴𝐶𝐷
𝑨 𝑩
(0,0)
100𝑡 0 + 75𝑡 37.5 + 75𝑡(37.5)
𝑥ҧ =
30,000 𝑁 100𝑡 + 75𝑡 + 75𝑡
𝑦ത
(𝑝𝑒𝑟 𝑠𝑖𝑑𝑒)
𝑪𝑮 100 ഥ = 𝟐𝟐. 𝟓 𝒎𝒎
𝒙
𝑚𝑚
𝑥ҧ σ 𝐴𝑖 𝑦𝑖 𝐴𝐴𝐶 𝑦𝐴𝐶 + 𝐴𝐴𝐵 𝑦𝐴𝐵 + 𝐴𝐶𝐷 𝑦𝐶𝐷
𝑦ത = =
σ𝐴 𝐴𝐴𝐶 + 𝐴𝐴𝐵 + 𝐴𝐶𝐷

100𝑡 50 + 75𝑡 0 + 75𝑡(100)

𝑪 𝑡 𝑫 𝑦ത =
100𝑡 + 75𝑡 + 75𝑡

ഥ = 𝟓𝟎 𝒎𝒎
𝒚
Relocate applied load
→ force couple system
= 𝑤𝑒𝑙𝑑𝑠

𝑨 75 𝑚𝑚
𝑩 𝑨 75 𝑚𝑚 𝑩
30,000 𝑁
𝑦ത = 50𝑚𝑚 𝐹𝐶𝐺 𝑦
(𝑝𝑒𝑟 𝑠𝑖𝑑𝑒)
𝑦ത = 50𝑚𝑚
100 𝑀𝐶𝐺 100
𝑪𝑮 𝑚𝑚 𝑚𝑚
𝑪𝑮
𝑥ҧ = 22.5𝑚𝑚 𝑥ҧ = 22.5𝑚𝑚

𝑪 𝑫 𝑪 𝑫
55 𝑚𝑚 𝑡 55 𝑚𝑚 𝑡

𝐹𝐶𝐺 𝑦 = 30,000 𝑁

𝑀𝐶𝐺 = 30,000𝑁 0.055𝑚 + 0.0225𝑚 = 2,325 𝑁𝑚

Primary and Secondary Shear Stresses
Primary Shear Stress (translational effects)

′
𝑉
𝜏 =
𝐴
𝑨 𝑩
Secondary Shear Stress (rotational effects)
𝐹𝐶𝐺 𝑦
𝑇𝑟
𝜏 ′′ = 𝑀𝐶𝐺
𝐽 𝑪𝑮

• Rotation occurs around centroid of weld group 𝑟3

𝑟1
o Draw a radial line from the centroid to anywhere 𝑟2
𝑫
on the weld group (green dashed line)
𝑪
o Stress and strain act perpendicular to the radial
line (purple arrow) Note: Stress/purple arrows represent what the applied
force is doing to the joint plate (through the welds)
Primary Shear Stress, 𝝉′
Primary Shear Stress (translational effects) 𝑨 75 𝑚𝑚 𝑩

𝐹𝐶𝐺 𝑦
𝑉 𝑦ത = 50𝑚𝑚
𝜏′ = 𝑀𝐶𝐺 100
𝐴 𝑚𝑚
𝑪𝑮
𝑥ҧ = 22.5𝑚𝑚
30,000 𝑁 30,000𝑁
𝜏′ = = 𝑪 𝑫
0.075𝑡 + 0.075𝑡 + 0.1𝑡 [𝑚2 ] 0.250𝑡 [𝑚2 ]
55 𝑚𝑚 𝑡
𝐹𝐶𝐺 𝑦 = 30,000 𝑁
′
120,000 Primary (translational)
𝜏 = [𝑃𝑎] shear at each location on
𝑡
weld group
Worst case for shearing stress
Things to consider:
• We should consider every vertex of the weld group could be possible candidate
locations for the worst case of shear stress in the joint
• r will be largest at these locations
• How does the primary shear stress add to the secondary shear? Are the primary
(translational) and secondary (rotational) stresses in the same direction, or are
they opposing?
𝑨 𝑩
𝐹𝐶𝐺 𝑦 Worst case locations are where ‘r’ is largest,
and primary and secondary shear is additive:
𝑀𝐶𝐺
Here, we don’t have a clear location where this
𝑪𝑮 condition occurs. Therefore we will need to
𝑫 find overall shear at each corner and pick
largest shear
𝑪
Secondary Shear Stress
Secondary Shear Stress (rotational effects)

′′
𝑇𝑟 𝑇 = 2,325 𝑁𝑚
𝜏 =
𝐽

𝑟𝐴,𝐵,𝐶,𝐷 = 𝑐𝑎𝑛 𝑓𝑖𝑛𝑑 (𝑘𝑛𝑜𝑤𝑛 𝑔𝑒𝑜𝑚𝑒𝑡𝑟𝑦)

𝑱 =?
Polar Moment of Inertia
Polar Moment of Inertia of Weld Group (about CG)
• Known weld group geometry
• Using table 9.1 in Shigley txtbk

Table 9.1 in the Shigley manual

𝑱 = 𝟎. 𝟕𝟎𝟕 𝒉 𝑱𝒖
𝒕
𝒕 = 𝟎. 𝟕𝟎𝟕𝒉 → 𝒉=
𝟎. 𝟕𝟎𝟕

8𝑏3 + 6𝑏𝑑 2 + 𝑑 3 𝑏4 8(75)3 +6 75 100 2

+ (100)3 (75)4
𝐽𝑢 = − = − = 613,020 𝑚𝑚3
12 2𝑏 + 𝑑 12 2(75) + (100)

𝑡
𝐽 = 0.707 ℎ 𝐽𝑢 = 0.707 𝐽 = 𝐽𝑢 𝑡
0.707 𝑢

𝑱 = 𝟔𝟏𝟑, 𝟎𝟐𝟎𝒕 𝒎𝒎𝟒 = 𝟔. 𝟏𝟑𝟎𝟐𝟎 × 𝟏𝟎−𝟒 𝒕 𝒎𝟒

Secondary Shear Stress 𝑨 75 𝑚𝑚 𝑩
𝐹𝐶𝐺 𝑦
𝑦ത = 50𝑚𝑚
𝑀𝐶𝐺 100
′′
𝑻𝒓 𝑇 = 2,325 𝑁𝑚
𝑚𝑚
𝝉 = 𝐽 = 6.13020 × 10−4 𝑡 𝑚4 𝑪𝑮
𝑱 𝑥ҧ = 22.5𝑚𝑚

𝑪 𝑫
𝑡

At Vertex A and C: At Vertex B and D:

𝑟= 0.075 − 0.0225 2 + (0.0502 )

𝑟= 0.0225 2 + (0.0502 )

𝑟 = 0.0548 𝑚 𝑟 = 0.0725 𝑚

2,325 𝑁𝑚 (0.0548 𝑚) 207,950 2,325 𝑁𝑚 (0.0725 𝑚) 280,461

𝜏 ′′ = = [𝑃𝑎] 𝜏 ′′ = = [𝑃𝑎]
6.13020 × 10−4 𝑡 𝑚4 𝑡 6.13020 × 10−4 𝑡 𝑚4 𝑡
 75 𝑚𝑚
𝑨 𝑩
Resultant Shear 𝑦ത = 50𝑚𝑚
𝐹𝐶𝐺 𝑦

𝑀𝐶𝐺 100
At Vertex D: 𝑚𝑚
𝑥ҧ = 22.5𝑚𝑚
𝑦
𝑪𝑮
𝜏𝑥 = 𝜏 ′′ 280,461 −0.05 193,421.38 𝑦
𝑟 =
𝑡 0.0725
=−
𝑡
𝑃𝑎 𝑪 𝑥 𝑫
𝑥 280,461 −0.0525 120,000 203,092.44 120,000 83,092.45 𝑥
𝜏𝑦 = 𝜏 ′′ + 𝜏′ = + = − 𝑃𝑎 + 𝑃𝑎 = 𝑃𝑎
𝑟 𝑡 0.0725 𝑡 𝑡 𝑡 𝑡 𝑦

210,514.1
𝜏= 𝜏𝑥2 + 𝜏𝑦2 = [𝑃𝑎]
𝑡

At Vertex B:
𝑦 280,461 −0.05 193,421.38
𝜏𝑥 = 𝜏 ′′ = = 𝑃𝑎
𝑟 𝑡 0.0725 𝑡
𝑥 280,461 −0.0525 120,000 203,092.44 120,000 83,092.45
𝜏𝑦 = 𝜏 ′′ + 𝜏′ = + =− 𝑃𝑎 + 𝑃𝑎 = 𝑃𝑎
𝑟 𝑡 0.0725 𝑡 𝑡 𝑡 𝑡

210,514.1
𝜏= 𝜏𝑥2 + 𝜏𝑦2 = [𝑃𝑎]
𝑡
 𝑥
𝑦
𝑨 𝑩
Resultant Shear 𝑦
𝐹𝐶𝐺 𝑦
𝑦ത = 50𝑚𝑚
𝑥 100
At Vertex A: 𝑀𝐶𝐺 𝑚𝑚
𝑥ҧ = 22.5𝑚𝑚
𝑦 𝑪𝑮
𝜏𝑥 = 𝜏 ′′ 207,950 0.05 189,735.40
𝑟 = = 𝑃𝑎
𝑡 0.0548 𝑡 𝑪 𝑫
𝑥 75 𝑚𝑚
𝜏𝑦 = 𝜏 ′′
+ 𝜏′ 207,950 0.0225 120,000 85,380.93 120,000 205,380.93
𝑟 = + = 𝑃𝑎 + 𝑃𝑎 = 𝑃𝑎
𝑡 0.0548 𝑡 𝑡 𝑡 𝑡

279,608.38
𝜏= 𝜏𝑥2 + 𝜏𝑦2 = [𝑃𝑎]
𝑡

At Vertex C:
𝑦 207,950 −0.05 189,735.40
𝜏𝑥 = 𝜏 ′′ = =− 𝑃𝑎
𝑟 𝑡 0.0548 𝑡

𝑥 207,950 0.0225 203,092.44 120,000 83,092.45

𝜏𝑦 = 𝜏 ′′ + 𝜏′ = = 𝑃𝑎 + 𝑃𝑎 = 𝑃𝑎
𝑟 𝑡 0.0548 𝑡 𝑡 𝑡
279,608.38
𝜏= 𝜏𝑥2 + 𝜏𝑦2 = [𝑃𝑎]
𝑡
Find Yield Strength in Shear
𝑆𝑠𝑦
𝜏=
𝑆𝐹

From Section 11.4 of J&M Txtbk, pg 478 paragraph 4:

“Specified yield strengths for E60 and E70 series welding rods are about 12 ksi below the tensile
strengths”

𝑆𝑦 = 60 𝑘𝑠𝑖 − 12 𝑘𝑠𝑖 = 48 𝑘𝑠𝑖

We also know, for steel (see eq. on pg 327):

𝑆𝑠𝑦 = 0.58 𝑆𝑦 = 0.58 48 𝑘𝑠𝑖 = 27.84 𝑘𝑠𝑖 → 1 𝑘𝑠𝑖 = 6.895 𝑀𝑃𝑎

𝑺𝒔𝒚 = 𝟏𝟗𝟏. 𝟗 𝑴𝑷𝒂

Weld Size Required
It was found that vertex A and C carry the highest shear stresses, therefore we
design based on these worst case:

𝑆𝑠𝑦 𝑡
𝜏= ℎ=
𝑆𝐹 0.707

279,608.38 191.9 × 106 𝑃𝑎 4.37 𝑚𝑚

𝑃𝑎 = ℎ=
𝑡 3 0.707

ℎ = 6.18 𝑚𝑚
𝒕 = 𝟒. 𝟑𝟕 × 𝟏𝟎−𝟑 𝒎 = 𝟒. 𝟑𝟕𝒎𝒎

Conservatively, we will tell welder to use

a weld leg of: ℎ = 7 𝑚𝑚 𝐴𝑁𝑆
Problem 5
Two 20-mm steel plates are butt-welded together. Both the plate and the
welding electrode materials have strength properties of 𝑆𝑢 = 500 𝑀𝑃𝑎 and
𝑆𝑦 = 400 𝑀𝑃𝑎. The imposed loading fluctuates rapidly between -20 and
+60kN. Estimate the length of weld required to provide a safety factor of 2.5 if:
(a) the weld reinforcement is not removed.
(b) the excess weld material is carefully ground off to provide smooth,
continuous surfaces.

𝑆𝑢 = 500 𝑀𝑃𝑎
P P
S𝑦 = 400 𝑀𝑃𝑎
𝑆𝐹 = 2.5
20mm
Assumptions

20mm

P P

1. If the weld “reinforcement” is not removed, the weld metal has a

rough surface—comparable to an “as-forged” surface
2. Infinite life is required for the application
3. The gradient factor, 𝐶𝐺 = 0.8 (middle of axial load range tbl 8.1 J&M)
We are dealing with a fatigue loading scenario due to rapidly fluctuating loading
(fluctuating between -20kN and +60kN)
• will use Modified Goodman Criterion
• will use stress concentration factor in fatigue, 𝐾𝑓

𝜎𝑎 𝜎𝑚 1
+ =
𝑆𝑛 𝑆𝑢 𝑛

Where the mean and alternating stresses are:

𝑃𝑚
𝜎𝑚 = 𝐾𝑓 **Cross sectional area of an open
𝐴
square butt joint will be square:
LxW**
𝑃𝑎 W=20mm, and question is asking
𝜎𝑎 = 𝐾𝑓
𝐴 for us to find length of weld
required, L.
(a) the weld reinforcement is not removed

If the weld reinforcement is not removed, the surface will remain rough, therefore, it
can be assumed that 𝐶𝑆 for the weld metal would correspond to an “as-forged” surface

Endurance Limit:
𝑺𝒏 = 𝑺𝒏′ 𝑪𝑳 𝑪𝑮 𝑪𝑺 𝑪𝑻 𝑪𝑹 (Eq 8.13 in J&M txtbk)

𝑆𝑛′ = 0.5𝑆𝑢 𝐶𝑇 =1 (dealing with temperatures below 450°C)

𝐶𝐿 = 1 (dealing with axial loading) 𝐶𝑆 =0.52 (for 𝑆𝑢 =500 MPa, 𝐶𝑆 ~ 0.52 – Fig 8.13 J&M)
𝐶𝐺 = 0.8 (middle of axial range) 𝐶𝑅 = 1 (reliability not specified, ∴ remain conservative with 50%)

𝑆𝑛 = 0.5 500𝑀𝑃𝑎 1 0.8 0.52 1 1 = 104 𝑀𝑃𝑎

(a) the weld reinforcement is not removed

Mean Load:
60𝑘𝑁 + −20𝑘𝑁
𝑃𝑚 = = 20 𝑘𝑁
2

Alternating Load:

60𝑘𝑁 − (−20𝑘𝑁)
𝑃𝑎 = = 40 𝑘𝑁
2
(a) the weld reinforcement is not removed

𝜎𝑎 𝜎𝑚 1 𝑃𝑎 𝐾𝑓 𝑃𝑚 𝐾𝑓 1
+ = → + =
𝑆𝑛 𝑆𝑢 𝑛 𝐴 𝑆𝑛 𝐴 𝑆𝑢 𝑛

Known: 𝑆𝑛 = 104 𝑀𝑃𝑎 𝑆𝑢 = 500 𝑀𝑃𝑎 𝑃𝑚 = 20 𝑘𝑁 𝑃𝑎 = 40 𝑘𝑁

𝐾𝑓 = 1.2 (𝑓𝑟𝑜𝑚 𝑡𝑏𝑙 11.2) 𝐴 = 𝐿 × 𝑊 = 𝐿 0.02𝑚

(40 × 103 )(1.2) (20 × 103 )(1.2) 1

+ =
(0.02 𝐿)104 × 10 6 0.02 𝐿 500 × 10 6 2.5 𝐿 = 64 𝑚𝑚 𝐴𝑁𝑆.
(b) the excess weld material is ground off

If the excess weld is ground off, the surface will be smooth and continuous, therefore,
we can use the surface factor, 𝐶𝑆 , for a fine-ground or commercially polished surface

Endurance Limit:
𝑺𝒏 = 𝑺𝒏′ 𝑪𝑳 𝑪𝑮 𝑪𝑺 𝑪𝑻 𝑪𝑹 (Eq 8.13 in J&M txtbk)

𝑆𝑛′ = 0.5𝑆𝑢 𝐶𝑇 =1 (dealing with temperatures below 450°C)

𝐶𝐿 = 1 (dealing with axial loading) 𝐶𝑆 =0.9 (for 𝑆𝑢 =500 MPa, 𝐶𝑆 = 0.9 – Fig 8.13 J&M)
𝐶𝐺 = 0.8 (middle of axial range) 𝐶𝑅 = 1 (reliability not specified, ∴ remain conservative with 50%)

𝑆𝑛 = 0.5 500𝑀𝑃𝑎 1 0.8 0.9 1 1 = 180 𝑀𝑃𝑎

(b) the excess weld material is ground off

𝜎𝑎 𝜎𝑚 1 𝑃𝑎 𝐾𝑓 𝑃𝑚 𝐾𝑓 1
+ = → + =
𝑆𝑛 𝑆𝑢 𝑛 𝐴 𝑆𝑛 𝐴 𝑆𝑢 𝑛

Known: 𝑆𝑛 = 180 𝑀𝑃𝑎 𝑆𝑢 = 500 𝑀𝑃𝑎 𝑃𝑚 = 20 𝑘𝑁 𝑃𝑎 = 40 𝑘𝑁

𝐾𝑓 = 1
(𝑟𝑒𝑔𝑢𝑙𝑎𝑟 𝑝𝑙𝑎𝑡𝑒 𝑠𝑖𝑡𝑢𝑎𝑡𝑖𝑜𝑛 𝑤𝑖𝑡ℎ 𝑛𝑜 𝑛𝑜𝑡𝑐ℎ (𝑞 = 0), 𝑠𝑒𝑒 𝑝𝑔 335 𝑖𝑛 𝐽&𝑀)
𝐴 = 𝐿 × 𝑊 = 𝐿 0.02𝑚

(40 × 103 )(1) (20 × 103 )(1) 1

6
+ 6
=
(0.02 𝐿)180 × 10 0.02 𝐿 500 × 10 2.5 𝐿 = 32.8 𝑚𝑚 𝐴𝑁𝑆.
See you next
week!