Mod 4 PRPC19 DME 2023
Mod 4 PRPC19 DME 2023
Lecture Notes
On
Design of welded and riveted joint
By
Dr. Prakash Kumar
Assistant Professor
Department of Production Engineering
NIT Tiruchirappalli
Syllabus
• Welded joints: types of joints, welding symbol and weld symbol and their
representation, strength of welded joints subjected to various types of load.
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 2
WELDED JOINTS
• Welding can be defined as a process of joining metallic parts by heating to a suitable
temperature with or without the application of pressure. Welding is an economical and
efficient method for obtaining a permanent joint of metallic parts.
• There are two distinct applications of welded joints—a welded joint can be used as a
substitute for a riveted joint and a welded structure as an alternative method for
casting or forging.
•Advantages of Welded Joints over Riveted Joints
1. The welded structures are usually lighter than riveted structures. This is due to the
reason, that in welding, gussets or other connecting components are not used.
2. The welded joints provide maximum efficiency (may be 100%) which is not possible
in case of riveted joints.
3. Alterations and additions can be easily made in the existing structures.
4. As the welded structure is smooth in appearance, therefore it looks pleasing.
5. In welded connections, the tension members are not weakened as in the case of
riveted joints.
6. A welded joint has a great strength. Often a welded joint has the strength of the
parent metal itself.
7. Sometimes, the members are of such a shape (i.e. circular steel pipes) that they afford
difficulty for riveting. But they can be easily welded.
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8. The welding provides very rigid joints. This is in line with the modern trend of
providing rigid frames.
9. It is possible to weld any part of a structure at any point. But riveting requires
enough clearance.
10.The process of welding takes less time than the riveting.
• Disadvantages
1. Since there is an uneven heating and cooling during fabrication, therefore the
members may get distorted or additional stresses may develop.
2. It requires a highly skilled labour and supervision.
3. Since no provision is kept for expansion and contraction in the frame, therefore there
is a possibility of cracks developing in it.
4. The inspection of welding work is more difficult than riveting work.
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 4
Welding joints
• Welded joint are divided in to two groups:
• Butt joints Fillet joints
A butt joint can be defined as a A fillet joint, also called a lap joint, is
joint between two components a joint between two overlapping
lying approximately in the same plates or components. A fillet weld
plane. A butt joint connects the consists of an approximately
ends of the two plates. triangular cross-section joining two
surfaces at right angles to each other.
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Butt joints
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 6
FILLET JOINTS
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Other welded joints
•
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Basic weld symbols
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Supplementary Weld Symbols
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Standard Location of Elements of a Welding Symbol
• A welding symbol consists of the following eight elements:
• 1. Reference line, 2. Arrow, 3. Basic weld symbols,
• 4. Dimensions and other data, 5. Supplementary symbols, 6. Finish symbols,
• 7. Tail, and 8. Specification, process or other references.
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Representation of welding symbols.
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Strength of Butt Weld
• The Average Tensile strength is P
t =
• Where , hl
• h = throat of the Butt weld(mm)
• P = tensile force(N) P P
P = t tl
• Throat of the weld can be considered equivalent to the thickness(t) of the plate
• Some codes (like code for unfired pressure vessel) suggest reduction in strength of a
butt welded joint by a factor called efficiency of the joint .
P = t tl
• where ,
η = efficiency of the joint.
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Numerical Problem 1 (NP1)
• A gas tank consists of a cylindrical shell of 3 m inner diameter. It is enclosed by
hemispherical shells by means of butt welded joint as shown in figure. The thickness
of the cylindrical shell as well as the hemispherical cover is 15 mm. Determine the
allowable internal pressure to which the tank may be subjected, If the permissible
tensile stress in the weld is 100 N/mm2. Assume efficiency of the welded joint as 0.95.
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Strength of Parallel Fillet Welds
• A parallel fillet weld subjected to a tensile force P is shown in Fig
t = h cos(45o )
or
t = 0.707h
Throat Leg
• Failure of fillet weld occurs due to shear along minimum cross section at the throat.
=
P
=
P P = 0.707hl
tl 0.707hl
P = 2(0.707 hl )
• Usually, there are two welds of equal length on two sides of the
vertical plate. In that case, or
P = 1.414hl
• In determining the required length of the weld, 15 mm should be added to the length
of each weld to allow for starting and stopping of the weld run.
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 15
Strength of Transverse Fillet Weld
• A transverse fillet weld subjected to a tensile force P is shown in Fig. The transverse
fillet welds are subjected to tensile stress. The minimum cross-section of the weld is at
the throat. o
t = h cos(45 )
or
t = 0.707h
• Failure of transverse fillet weld occurs due to tensile stress along minimum cross
section at the throat.
t = =
P P P = 0.707hl t
tl 0.707hl
• Usually, there are two welds of equal length on two sides of the vertical plate. In that
case, = permissible tensile stress for the weld (N/mm2)
P = 2(0.707hl t ) t
h = leg of the weld (mm)
or l = length of the weld (mm)
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Numerical Problem 3 (NP3)
• Two steel plates, 100 mm wide and 10 mm thick, are joined together by means of
double transverse fillet welds. The maximum tensile stress for the plates and the
welding material should not exceed 110 N/mm2. Find the required length of the weld,
if the strength of weld is equal to the strength of the plates.
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Numerical Problem 4 (NP4)
• A steel plate, 120 mm wide and 12.5 mm thick, is joined with another steel plate by
means of single transverse and double parallel fillet welds, as shown in Fig. The
strength of the welded joint should be equal to the strength of the plates to be joined.
The permissible tensile and shear stresses for the weld material and the plates are 80
and 50 N/mm2 respectively. Find the length of each parallel fillet weld. Assume the
tensile force acting on the plates as static.
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 19
Maximum Shear Stress in Parallel Fillet Weld
• A double parallel fillet weld of equal legs subjected to a force of (2P) is shown in Fig.
It is required to find out the inclination (q) of the plane in the weld, where maximum
shear stress is induced and also, the magnitude of the maximum shear stress. The
effect of bending is to be neglected.
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Maximum Shear Stress in Transverse Fillet Weld
• A double transverse fillet weld of equal legs is subjected to a force (2P) as shown in
Fig. It is required to find out the inclination (q) of the plane in the weld where the
maximum shear stress is induced and also, the magnitude of the maximum shear
stress. The effect of bending is to be neglected.
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Numerical Problem 5 (NP5)
• A 150 × 120 × 10 mm angle is to be welded to a steel plate by fillet welds. If the angle
is subjected to a static load of 200 kN, find the length of weld at the top and bottom.
The allowable shear stress for static loading may be taken as 75 MPa.
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 23
Eccentric Load in The Plane of Welds
• A bracket subjected to an eccentric force P and attached to the support by means of
two fillet welds W1 and W2 is shown in Fig
• The force P acting through the centre of gravity causes direct shear stress in the welds.
It is called the primary shear stress.
• The couple M causes torsional shear stresses in the throat area of welds. They are
called secondary shear stresses and given by
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Numerical Problem 6 (NP6)
• A welded connection, as shown in Figure is subjected to an eccentric force of 10kN.
Determine the size of welds if the permissible shear stress for the weld is 100 N/mm2.
Assume static conditions.
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Welded Joint Subjected to Bending Moment
• A cantilever beam of rectangular cross-section is welded to a support by means of two
fillet welds W1 and W2 as shown in Fig.
• The bending stresses are assumed to act normal to the throat area. The resultant shear stress in
the welds is given by,
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Numerical Problem 7 (NP7)
• A beam of rectangular cross-section is welded to a support by means of fillet welds as
shown in Figure. Determine the size of the welds, if the permissible shear stress in the
weld is limited to 90 N/mm2.
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• A circular beam, 50 mm in diameter, is welded to a support by means of a fillet weld
as shown in Fig. Determine the size of the weld, if the permissible shear stress in the
weld is limited to 100 N/mm2.
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Welded Joint Subjected to Torsional Moment
• A shaft of circular cross-section is welded to the plate by means of a circumferential
fillet weld as shown in Fig. The shaft is subjected to torsional moment Mt that induces
torsional shear stresses in the weld.
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Numerical Problem 8 (NP8)
• A circular shaft of 70 mm diameter, is welded to the support by means of
circumferential fillet weld as shown in Figure. It is subjected to torsional moment of
3500 N-m. Determine the size of the weld, if the permissible shear stress in the weld
is limited to 140 N/mm2.
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Welded Joints Subjected to Fluctuating Forces
• When a welded joint is subjected to a static force, the effect of stress concentration is
neglected.
• However, stress concentration is an important
consideration while designing a welded joint
subjected to fluctuating force.
• In static loading, the effect of stress concentration,
surface finish and reliability factor, are not taken
into account.
• Ka= surface fi nish factor; Kb = size factor; Kc = reliability factor depending on reliability of
weld under for fatigue failure; Kd = factor due to stress concentration = 1 /SCF= 1/ Stress
concentration factor.
•
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Numerical Problem 9 (NP9)
• Two plates, 20 mm thick, are welded together by means of a reinforced butt weld and
subjected to a completely reversed axial load of ± 120 kN. The throat of the weld is 20
mm. The ultimate tensile strength of the weld metal is 500 N/mm2. The surface fi nish
of the weld is equivalent to that of the forged component and the reliability is 90%.
Determine the length of the weld if the factor of safety is 2.
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Practice problem
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 33
RIVETED JOINTS
• A rivet is a short cylindrical bar with a head integral to it. The
cylindrical portion of the rivet is called shank or body and lower
portion of shank is known as tail. The rivets are used to make
permanent fastening between the plates such as in structural work,
ship building, bridges, tanks and boiler shells. The riveted joints are
widely used for joining light metals.
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• Riveting methods are also classified on the basis of temperature of the shank
✓Hot Riveting and Cold riveting
• In hot riveting shank is subjected to tensile stress.
• In Cold riveting the shank manly subjected to shear stress.
• Cold riveting applicable for steel rivets up to 8 to 10 mm, mostly used for non ferrous
metals.
• There are two methods Making holes in plates
• Punching and drilling
• Punching is cheaper than drilling.
• Hole location and size accuracy is less in Punching
• Punching injure metal in the vicinity
• Punching is feasible only for thin plates up to 25 mm
• Traditional Mechanical structures involved riveted joints are classified into three groups:
✓Boilers, pressure Vessel and Tanks;
✓Bridges, truss, cranes and machinery in general; and
✓Hulls of ship
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 35
Riveted Joints Vs Welded joints
• Riveted joints create no Heat effected zone
• Riveted joints are used for metals with poor weld ability like aluminum.
• Can join dissimilar materials
• Better resistance to vibrations and impact load
• Suitable for thin plates, aircraft structures.
• Quality can be easily checked
• On dismantling connected component less damaged.
• Disadvantages of Riveted joints
• The material cost of rivet joint is more, more thicker plates as compared to required
for welding, more weight due to rivets
• The labour cost is more.
• Riveting process create more noise.
• Holes creates stress concentration.
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TYPES OF RIVET HEADS
•
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TYPES OF RIVETED JOINTS
• Riveted joints used for joining the plates are classified into two groups—lap joint and
butt joint.
• Lap joint consists of two overlapping plates, which are held together by one or more
rows of rivets as shown in Fig.
• Depending upon the number of rows, the lap joints are further classified into single-
riveted lap joint, double-riveted lap joint or triple riveted lap joint.
• In double or triple riveted lap joints, the rivets can be arranged in chain pattern or zig-
zag pattern as shown in Fig. (b) and (c) respectively.
• A chain riveted joint is a joint in which the rivets are arranged in such a way that
rivets in different rows are located opposite to each other.
• A zig-zag riveted joint is a joint in which
the rivets are arranged in such a way that
every rivet in a row is located in the
middle of the two rivets in the adjacent
row.
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 38
Terminology of riveted joints:
• Pitch (p): It is defined as the distance between the center of one rivet to the center of
the adjacent rivet in the same row. Usually p=3d
• Margin (m): It is the distance between the edge of the plate to the centreline of rivets
in the nearest row. Usually m = 1.5d
• Transverse Pitch (pt) Transverse pitch, also called back pitch or row pitch, is the
distance between two consecutive rows of rivets in the same plate. Usually,
pt = 0.8p (for chain riveting)
= 0.6p (for zig-zag riveting)
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 39
TYPES OF FAILURE
• The types of failure in riveted joints are illustrated in Figure below. According to
conventional theory, the failure of the riveted joint may occur in any one or more of
the following ways:
• (i) shear failure of the rivet;
• (ii) tensile failure of the plate between two consecutive rivets;
• (iii) crushing failure of the plate;
• (iv) shear failure of the plate in the margin area; and
• (v) tearing of the plate in the margin area.
• Based upon the above-mentioned criteria of failure, strength equations are written for
riveted joints.
Types of Failure in Riveted Joint (a) Shear Failure of Rivet (b) Tensile
Failure of Plate between Rivets (c) Crushing Failure of Plate by Rivet
(d) Shear Failure of Plate by Rivet (e) Tearing of Margin
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 40
STRENGTH EQUATIONS
• The strength of riveted joint is defined as the force that the joint can withstand without
causing failure. In analysis of riveted joints, mainly three types of failure are
considered. They are as follows:
• (i) shear failure of the rivet;
• (ii) tensile failure of the plate between rivets; and
• (iii) crushing failure of the plate.
• Based on the above criteria of failure, the strength equations are derived.
• (i) Shear Strength of Rivet: In case of single riveted lap join
• In case of double or triple riveted lap join
• where, Ps = shear resistance of rivet per pitch length (N)
• d = shank diameter of rivet (mm)
• = permissible shear stress for rivet material (N/mm2)
• n = number of rivets per pitch length. For double-riveted joint, n = 2
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• (ii) Tensile Strength of Plate between Rivets:
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Numerical Problem 10 (NP10)
• A double-riveted, single-row butt joint is used to connect two plates of thickness 22
mm each. The diameter of the rivets is 30 mm each. The pitch between the rivets is
100 mm. The load applied on the plates is such that the tensile stress developed in the
plates is 75 MPa. What are the shearing and bearing stresses in the rivets? What is the
thickness of the cover plates?
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Numerical Problem 11 (NP11)
• Two flat plates subjected to a tensile force P are connected together by means of
double-strap butt joint as shown in Figure. The force P is 300 kN and the width of the
plate w is 225 mm. The rivets and plates are made of the same steel and the
permissible stresses in tension, compression and shear are 80, 120 and 60 N/mm2
respectively. Calculate:
• (i) the diameter of the rivets;
• (ii) the thickness of the plates;
• (iii) the dimensions of the seam, viz., p, pt and m; and
• (iv) the efficiency of the joint.
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EFFICIENCY OF JOINT
• The efficiency of the riveted joint is defined as the ratio of the strength of riveted joint
to the strength of unriveted solid plate.
• The strength of the riveted joint is the lowest value of Ps, Pt and Pc .
• The strength of solid plate of width, equal to the pitch p and thickness t, subjected to
tensile stress t is given by,
• Therefore, the efficiency is given by,
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• (ii) Diameter of Rivet:
• (a) When the thickness of plate is more than 8 mm,
• (b) When the thickness of the plate is less than 8 mm, the diameter of rivet is obtained
by equating shear resistance of rivets to crushing resistance.
• (c) In no case, should the diameter of the rivet be less than the plate thickness.
• (iii) Pitch of Rivet: the pitch of the rivets in the outer row is maximum.
n1 = number of rivets subjected to single shear per pitch length
n2 = number of rivets subjected to double shear per pitch length
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• (iv) Transverse Pitch (pt):
• Case I In a lap or butt joint, in which there are more than one row of rivets and in
which there is an equal number of rivets in each row, the minimum distance between
the rows of rivets is given by,
• Case II In joints in which the number of rivets in the outer row is one-half of the
number of rivets in each of the inner rows and in which the inner rows are zigzag
riveted, the minimum distance between the outer row the and next row is given by,
• The minimum distance between the rows in which there are full number of rivets is given by,
• (v) Margin (m) The distance between the centre of the rivet hole from the edge of the
plate is called margin. The minimum margin is given by,
• m = 1.5d
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• (vi) Thickness of Straps (t1)
• Case I When the straps are of unequal width and in which every alternate rivet in the
outer row is omitted,
• t1 = 0.75t (for wide strap)
• t1 = 0.625t (for narrow strap)
• Case II When the straps are of equal width and in which every alternate rivet in outer
row is omitted, The thickness of the strap, in no
case, shall be less than 10 mm.
• (vii) Permissible Stresses: Assuming a factor of safety of 5, the permissible tensile and shear
stresses are given by,
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Numerical Problem 12 (NP12)
• A boiler drum of internal diameter 1.5 m is to be designed to sustain internal pressure
of 2.0 N/mm2. Taking efficiency of longitudinal joint as 75%, determine the thickness
of the plate. Take factor of safety as 5, and design a double-cover, double-riveted butt
joint along the length of boiler drum. What is the efficiency of the joint? For the
material σut = 420 MPa, σuc = 640 MPa, τu = 330 MPa. Assume that the rivets in
double shear are 1.875 times stronger than in single shear and the joint do not fail by
crushing. Calculate:
• (i) thickness of the plate;
• (ii) diameter of the rivets;
• (iii) pitch of the rivets;
• (iv) distance between inner and outer rows of the rivets;
• (v) margin;
• (vi) thickness of the straps;
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Circumferential Lap Joint For Boiler Shell
• The circumferential lap joint is used to connect different cylindrical rings together and
form the boiler shell. In this case, one ring is kept overlapping over another ring and
the two rings are fastened by circumferential riveted joint. This type of joint is also
used to connect the end cover to the cylindrical shell.
• The design of circumferential lap joint consists of the following steps:
• (i) Thickness of Cylindrical Shell: same as longitudinal
butt joint.
• (ii) Diameter of Rivet: same as longitudinal butt joint.
• (iii) Number of Rivets: As shown in Fig., the
rivets are subjected to single shear. Equate total shear
resistance of all rivets to external force acting on the joint. by,
• The pitch p1 obtained by the above procedure has minimum and maximum limits like
the pitch of longitudinal joint
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Numerical Problem 13 (NP13)
• Cylindrical pressure vessel with 1 m inner diameter is subjected to internal steam
pressure of 1.5 MPa. The permissible stresses for the cylinder plate and the rivets in
tension, shear and compression are 80, 60 and 120 N/mm2 respectively. The efficiency
of longitudinal joint can be taken as 80% for the purpose of calculating the plate
thickness. The efficiency of circumferential lap joint should be at least 62%. Design
the circumferential lap joint and calculate:
• (i) thickness of the plate;
• (ii) diameter of the rivets;
• (iii) number of rivets;
• (iv) pitch of rivets;
• (v) number of rows of rivets; and
• (vi) overlap of the plates.
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Eccentrically Loaded Riveted Joint
• Structural members connected by rivets are often subjected to twisting moment due to
eccentric loading, which causes the development of torsional shear stress in addition
to direct shear stress in rivets. Depending on the eccentricity, the torsional shear stress
may assume high proportions and the direct shear stress becomes negligible. Such
joints must be carefully designed in order to avoid any damage to the structure.
• P = Eccentric load on the joint, and
• e = Eccentricity of the load
(1) First of all, find the centre of gravity G of the rivet system
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• (3) P1 = P is to produce direct shear load on each rivet of equal magnitude. Therefore,
direct shear load on each rivet,
The direction of these forces F1, F2 .. are at right angles to the lines
joining the centre of rivet to the centre of gravity of the rivet system
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• (5) The primary (or direct) and secondary shear load may be added vectorially to
determine the resultant shear load (R) on each rivet.
• When the secondary shear load on each rivet is equal, then the heavily loaded rivet
will be one in which the included angle between the direct shear load and secondary
shear load is minimum. The
• The maximum loaded rivet becomes the critical one for determining the strength of
the riveted joint.
• Knowing the permissible shear stress (τ), the diameter of the rivet hole may be
obtained by using the relation,
25-11-2023 Lecture notes on Design of welded and riveted joint, by Dr. Prakash Kumar 56
Numerical Problem 14 (NP14)
• A bracket is attached to a steel channel by means of nine identical rivets to carry a
load of 45 kN as shown in Fig. Determine the diameter of rivets, if the permissible
shear stress is 50 N/mm2.
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Lecture notes on Design of welded and riveted joint, by Dr.
25-11-2023 58
Prakash Kumar