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Chapter
12
his is the third of three chapters that discusses the design for combined
loads. The previous two chapters dealt with the design of members subjected to the combined loads of axial and bending or torsion and bending.
This chapter discusses the design of fillet welds. The distance along one or
more sides of a member or the perimeter around the member influences the
size of the weld, which has an upper limit. There are design situations where
a cross-sectional shape is selected in order to obtain adequate weld length.
The base length of most brackets is defined by the length of the weld required to support the loading.
The actual design of the members becomes an iterative process: perform
the structural analysis, select a cross-sectional shape, and design the connection. If the welded connection requires a change in the cross-sectional shape,
select a new member. Plane frames and plane grids, however, are statically
indeterminate and any change in the cross-sectional properties requires a
new structural analysis. The procedure goes on until all of the stress and deflection ratios satisfy the design criteria. Since the length requirements of a
weld influences the selection of a cross section, the material related to the
analysis and design of welded joints is an integral part of the design for
combined loadings.
The design of welded connections is covered in several machine design
and structural design books, but there is a lack of consistency in the presentations. Every book discusses the analysis of welded connections subjected
to shear and torsion loads while fewer books discuss the analysis of connections subjected to an axial force and a bending moment similar to what occurs in a beam. Even fewer books discuss the analysis of connections
362
subjected to the combined loadings of axial, shear, and bending, which are
very common in plane frames, and the combined loadings of torsion, shear,
and bending, which occur in plane grids. Several books give the basic ingredients for analyzing these loading situations, but they do not work complete
examples nor do they combine the design of a weld with the design of a
member.
A systematic procedure for analyzing and designing welded joints subjected to combined loadings is presented in this chapter. The approach is
unique in several ways and the information presented is used in the designs
presented in Chapter 13 and the design projects outlined in Chapter 14.
363
USCS:
SI:
Qall =
42.4 w
kips/in
N
0.293 w
kN/mm
N
Qall =
(12.1)
(12.2)
SI:
49.5w
kips/in
N
(12.3)
0.341 w
kN/mm
N
(12.4)
Qall =
Qall =
The dimension of the weld leg, w, is known in analysis problems and is the
one of the variables in a design problem.
364
x
y
forces Py and Pz act in the plane of the weld. A weld can also be subjected to
moments about the x and z axes, Mx and Mz. The way in which a bracket is
attached to a member defines the type of forces and moments acting on the
weld and influences the size and shape of the weld.
Consider the brackets in Figure 12.2. These are subjected to a tension
load applied by a hydraulic cylinder. The bracket in Figure 12.2(a) is attached to the top of the structural section using a pair of welds that are subjected to an axial force Px, a shear force Py, and a moment about the z axis,
Mz. This moment is similar to the bending moment that occurs in beams and
the weld pattern is said to be subjected to bending. The shear flow values for
this weld act in the x and y directions. Attaching the bracket to the side of
the structural section changes the loads significantly. There are two shear
forces, Py and Pz, and the moment acts about the x axis. This moment, Mx, is
twisting the weld and the weld is said to be in torsion. All of the shear flow
y
y
z
z
(a)
(b)
365
values for this weld are in the y-z plane. The analysis of the connection in
Figure 12.2b is covered in nearly every book that discusses welded joints.
The analysis of the weld joint in Figure 12.2a is discussed less often. Both
types of welds are important and are discussed in detail in this chapter.
ave =
P
P
=
Aw t Lw
(12.5)
where t is the throat dimension (see Figure 6.5) and Lw is the effective
length. The shear area Aw = tLw is used in the calculation even though it is
not perpendicular to the normal stress. The average shear stress for the shear
forces Py and Pz are
y ,ave =
Py
and z ,ave =
t Lw
Px
y
Pz
t Lw
(12.6)
x
y
ave
z
Lw
Pz
Lw
z.ave
(b)
(a)
x
Py
Lw
z
(c)
y ,ave
366
Multiplying through (12.5) and (12.6) by the thickness t gives the respective
shear flow equations.
qx =
Px
Py
P
, qy =
, and qz = z
Lw
Lw
Lw
(12.7)
I=
2th3 t h3
=
12
6
(12.9)
Since the strength of the weld is assumed to be independent of the type and
direction of the stress and since equal maximum values occur at y = h/2,
Mz h
Mz
=
3 2
t h t h3
6
3
(12.10)
x
Figure 12.4 The normal stress distribution resulting from Mz.
Mz
367
The normal stress is multiplied by the throat thickness to obtain a shear flow
and the rest of the denominator is defined as a weld section property Zw as
qx = t =
Mz
h
3
3
Mz
Zw
(12.11)
The bending section property Zw for a pair of welds parallel to the y axis is
Zw =
h3
3
(12.12)
The weld section property equations for common shapes that are symmetrical relative to the z axis are presented in Table 12.1. These equations
were obtained using
I 1
Z w = = y 2 dA
c c A
(12.13)
where each weld is a line segment of unit width and c is one-half the weld
dimension parallel to the y axis.
The evaluation of (12.13) is illustrated by evaluating the section property
Zw when the weld pattern consists of two welds parallel to the z axis with the
dimensions b and h as shown in Table 12.1 (Case 3). The section property
Zw is
Zw =
1 2
y dA
c A
Since there is a pair of welds and c = h/2 while dA = (1)dz, the integral for
Zw is
2
b/2
2
h
Zw =
2 (1) dz
h/ 2 -b/2
which equals
Zw = b h
(12.14)
Weld patterns that lack symmetry relative to the z axis can be analyzed
using (12.8) where
I = y 2 dA
(12.15)
A
368
Table 12.1
Section properties of fillet welds.
Shape
Bending
Torsion
Z w=
h
6
Z w=
h
3
J w=
h
12
y
z
J w=
h( 3b 2 + h 2 )
6
y
z
Z w= b h
J w=
2
3
b + 3 bh
6
y
z
z
h
Z w= b h+
b
z=
h
6
J w=
(b + 2 h)3 b 2(b + h )2
( 2b + h)
12
b2
(2b + h)
y
z
h
Z w= b h+
3
J w=
(b + h )3
6
y
z
2
Z w= r
3
J w= 2 r
369
J = r 2 dA = ( x 2 + y 2 ) dA
A
(12.17)
Mx r
(12.18)
t r 2 dA
A
(12.19)
J w = r 2 dA
(12.20)
t = q=
where
dz
r
z
y
+
Mx
b
Figure 12.5 A pair of welds subjected to a twisting moment.
370
J w = ( y 2 + z 2 ) dA = 2
A
Jw =
which equals
b/2
z 2 dz + 2
-b/2
b/2
h
2 dy
-b/2
3hb + b3
6
(12.21)
Equations for Jw for several common weld patterns are given in Table 12.1.
A more extensive list is given in Hall et al. (1961).
The section properties Zw and Jw as given in Table 12.1 have different
units because the location of the maximum shear flow is built into Zw while
(12.19) is left in terms of a radial distance r. The shear flow q is assumed
to act perpendicular to r and must be resolved into y and z components before it can be combined with other shear flow values. Consider the location
shown in Figure 12.6. The radial distance r has an angle relative to the y
axis. The y and z components of the shear flow are
q y = q sin
qz = q cos
(12.22)
and
qz = -
M x r sin M x z
=
Jw
Jw
(12.23)
M x r cos
M y
=- x
Jw
Jw
(12.24)
371
q
a
r
z
qy
Mx
qz
(12.25)
y ( Li ) = yi Li
(12.26)
which becomes
I z = z 2 dL
L
(12.27)
(12.28)
where Io is (12.27) about the centroid of the line, L is the length of the line,
and d is the distance between the centroid of the line and the z axis.
The evaluation of the polar moment of inertia for a line segment parallels
the evaluation for an area
J = r 2 dL = ( y 2 + z 2 ) dL
L
(12.29)
(12.30)
372
where r is the radial distance from the point to the centroid of the line segment, and Jo is the polar moment of inertia for the line segment about its
centroidal axis. The value for Jo is the first selection in Table 12.1 and
(12.30) becomes
L3
J w = + Ly 2 + Lz 2
(12.31)
12
Example 12.1
150 mm
Evaluate Jw for the weld pattern consisting of three straight line segments as
shown. The weld size is 6 mm.
100
80
Solution:
The first step is to determine the dimensions of the effective length of each
weld. This is done by keeping the centroid of each line segment at its original position. The y and z axes, shown below, are used as the reference point
for determination of the centroid of the weld pattern which has a horizontal
axis of symmetry. The location of horizontal centroid z is given by
z=
The reference point for determining the centroid and the final set of dimensions for the effective weld pattern are shown below.
69.5 70.5
68
75
y
z
75
z'
138 mm
y'
150
138 mm
140
68
373
Jw = (
Jw =
L3
+ L( y 2 + z 2 )
12
683
1383
+ 138(0 + 69.5) 2 + 2
+ 68(752 + 70.52 )
12
12
Example 12.2
Evaluate Zw for the symmetric weld pattern shown. The bracket has an open
area to accommodate a structural component. The weld size is 1/4 inch.
Solution:
The dimensions of the original (left) and effective weld (right) are shown
below.
10
3 in
3.5
3.5
3 in
y
2.5
2.5
The centroid of each weld segment retains its original value. Note that the
weld segments are symmetrical about the z axis, therefore, the parallel-axis
theorem must be used with each segment. Since each segment has the same
dimensions
I z = 4 I z' + Ld 2
where I z' is the area moment about its centroidal axis. The evaluation of Zw
follows the calculation of Iz. Substituting the appropriate values gives
(2.5 in)3
h3
+ (2.5 in)(3.5 in)2 = 127.7 in3
I z = 4 + hd 2 = 4
12
12
374
The section property Zw = Iz/c where c is the distance from the z axis to the
outer most location or
Zw =
Iz
127.7 in 3
=
= 26.9 in 2
c [3.5 + (2.5 / 2)]in
(12.32)
(12.33)
qx
375
qy
Due to Py
qz
Py
qz
qy
qz
qy
Mx
Pz
qy
Due to Pz
qy
qz
qz
are selected because qy and qz obtain the largest values when the distances z
and y in (12.23) and (12.24) have their maximums. There is at least one location where the qy value resulting from Mx adds to the qy value resulting
from Py. The combined equation is
qy=
Py
Lw
Mxz
Jw
(12.34)
This equation holds when either one of Py or Mx are negative or when both
are negative. The same situation is true for qz and
qz =
Pz M x y
+
Lw
Jw
(12.35)
Equations (12.33) through (12.35) are the shear flow equations for a
weld subjected to a set of combined loadings. When one or more forces or
moments are zero, the corresponding terms are deleted. The joints in plane
frames and the brackets welded to the top or bottom of a member usually
support Px, Py, and Mz loadings and the terms containing Pz and Mx disappear. Brackets welded to the side of a member support Py, Pz, and Mx loadings and the terms containing Px and Mz disappear. The joints in a plane grid
support Py, Mx, and Mz and the terms containing Px and Pz are absent.
The location of the maximum shear flow QR is usually determined by inspection when doing hand calculations. Computer analyses of welded joints
usually incorporate a sign with the magnitude of the load and provide the
location of QR as part of the output.
376
(12.36)
The first example is a welded joint from a plane frame. The second example is a joint from a plane grid. The forces acting on these joints are obtained from a structural analysis as discussed in Chapter 10 or 11. The third
example is a bracket supporting a hydraulic cylinder.
The analysis problem is relatively straightforward. You evaluate all of the
parameters and check the shear flow ratio (12.36). The only item to be careful about is the effective length of the welds. The AISC ASD manual does
not allow the start and stop distances to be included in the calculations of
single welds, but it does allow the use of the actual length when the weld
goes around a corner. We will hold true to this requirement in both the
analysis and design calculations, although many books that discuss the
analysis and design of fillet welds do not subtract the start and stop lengths.
We start our calculations by determining the effective weld dimensions
when necessary. When the weld consists of intermittent welds, we will keep
the centroid of each weld in its original location.
377
Px = 4.91 kips
#72
M z = 28.7 kipin
Py = 3.54 kips
Figure 12.9 The support forces for a fixed joint in a plane frame.
The allowable shear flow is given by (12.1)
Qall =
49.5w 49.5(0.1875)
=
= 3.31 kips/in
N
2.80
(12.37)
The section property Zw for bending is obtained from Table 12.1 Using
the outside dimension, since the welds goes around the corners, gives
Z w = (b )( h ) +
h2
52
= (3)(5) +
= 23.3 in 2
3
3
Px M z
4.91 kips 28.7 kip in
+
=
+
= 1.54 kips/in
16.0 in
Lw Z w
23.3 in 2
qy =
Py
Lw
3.54 kips
= 0.221 kips/in
16.0 in
(12.38)
(12.39)
which is more than adequate. The engineer would investigate whether a 1/8
378
inch weld is adequate if this was a design problem. If the weld had not been
adequate, the engineer is faced with the decision of whether to increase the
weld size or change the cross-sectional shape of the tube to increase the
weld length.
Qall =
0.341w 0.341(4)
=
= 0.455 kN/mm
N
3.0
(12.40)
y
y
z
#9
0.250 m
6.70 kN
0.750 m
6.70 kN
Py = 6.70 kN
Mz = 5.03 kNm
Mx = 1.68 kNm
379
h2
762
= 76(76) +
= 7700 mm 2
3
3
Jw =
Three different shear flows occur in the weld, qx, qy, and qz. The shear
flow in the x direction results from the bending moment and is
qx =
M z 5 030 kNmm
=
= 0.653 kN/mm
Zw
7 700 mm 2
(12.41)
The shear flow in the y direction is composed of the two components given
in (12.34). The largest value occurs at the corner. We use values of 38 mm
(76/2) for the y and z directions in (12.34) and (12.35).
qy =
Py
Lw
Mxz
Jw
(12.42)
qy =
The third shear flow, qz, results from the torsion moment and is
qz =
M x y (1 680)(38)kNmm 2
=
= 0.109 kN/mm
Jw
585 300mm3
(12.43)
(12.44)
QR = 0.6532 + 0.1312 + 0.1092 = 0.675 kN/mm
380
QR 0.675 kN/mm
=
= 1.48 > 1
Qall 0.455 kN/mm
(12.45)
The weld is not adequate. This result was obvious from (12.41). Anytime
one of the shear flow components exceeds the allowable value, the weld is
inadequate. You should do all of the calculations, however, in order to determine which loading governs the design. In this example, the bending
moment governs the design and a rectangular tube is probably more appropriate for the primary structural component.
64 kN
20
30 kN
137.6
75
40
y
76
80
50
180 mm
17.4
y
180 mm
Since the weld is on the side of the member, the x axis is perpendicular to
the page and the applied force can be resolved into y and z components of
10.9 kN and 30 kN, respectively. The effective values for b and h are b =
180 mm and h = 80 4 = 76 mm. The weld size is only subtracted from the
ends of the vertical welds. The distance in the y direction from the weld to
the centroid of the weld pattern can be obtained from Table 12.1 by interchanging the variable names or from Hall et al. (1961). The location of the
centroid from the base, b, is
2
y=
( 76 mm )
h2
=
= 17.4 mm
b + 2h 180 + 2 ( 76 ) mm
The force components and the dimensions for the effective weld are also
381
shown in Figure 12.11. The shear force values are Py = 10.9 kN and Pz = -30
kN. The bottom or horizontal portion of the weld remains 155 mm from the
applied load. The moment about the x axis is
+
A visual inspection indicates the location A is the critical location where the
y and z shear flow components resulting from Mx add to the components
produced by the two shear forces.
The section properties for the weld are
Lw = b + 2h = 180 + 2(76) = 332 mm
Jw =
(b + 2h)3 h 2 (b + h) 2
12
(b + 2h)
Jw =
qy =
Py
Lw
M x z 10.9 3 692(90)
=
+
= 0.207 kN/mm
Jw
332 1 909 362
while qz is
qz =
Pz M x y 30 3 692(76 17.4)
+
=
+
= 0.204 kN/mm
332
1909 362
Lw
Jw
0.293w 0.293(4)
=
= 0.426 kN/mm
N
2.75
382
0.341w
= 0.675 kN/mm = QR
N
(12.46)
383
PROBLEMS
time the value of b and/or h is changed, the location of the weld centroid
changes and Mx must be re-evaluated. The evaluation of Mx can be incorporated into a spreadsheet with proper planning. The spreadsheet is usually
developed specifically for this type of bracket rather than for the shape of
the weld.
Problems
12.1 Verify the equation for Jw given in Table 12.2 for a pair of vertical
welds.
12.2 Verify the equations for Jw given in Table 12.2 for the circle.
12.3 Evaluate the section property equation Zw for the group of four welds
shown. Each weld has a length of h and the spacing between each pair
is h. Do the evaluation by (a) evaluating the integral in (12.13) and
(b) using the parallel-axis theorem in (12.28).
y
y
h
z
h
h
x
b
h
b
P12.3
P12.4
12.4 Determine the section property equation Jw for the group of four
welds in P12.4 above. Each weld has a length b and the spacing between each pair is b. Do the evaluation by (a) using the integral in
(12.29) and (b) using the parallel-axis theorem in (12.31).
12.5 Rectangular tubes welded to the supports are subjected to the support
forces given in the table below. The tube is defined by the section
code SC while the weld leg dimension is given by w. Determine
whether the welds are adequate when N = 2.75 and an E60 rod is
used. The member is welded on each side but the welds are discontinuous at each corner. The effective length of each weld is the member dimension minus the start-and-stop distances. The positive
direction for each force or moment is in the positive coordinate direc-
384
tions as shown in Figure 12.1. The 1-1 axis of the section is aligned
with the z axis. Information is provided in each system of units. The
reader is encouraged to develop a spreadsheet to solve the problems.
USCS Units
Problem
(a)
(b)
(c)
(d)
SC
58
62
71
86
w, in
0.2500
0.1250
0.1875
0.2500
Px, kips
6.40
8.60
17.3
15.6
Py, kips
3.20
3.10
9.50
12.4
M, kipin
22.5
12.3
22.7
52.4
Py, kN
14.2
13.8
42.3
55.2
Mz, kNmm
2540
1390
2560
5920
SI Units
Problem
(a)
(b)
(c)
(d)
SC
58
62
71
84
w, mm
6
4
5
6
Px, kN
28.5
38.3
77.0
69.4
(a)
1.25 in
32 mm
L
(b)
6 in
150 mm
4 in
100 mm
Problems 12.6 12.7 The brackets for these problems, below, have a pair of
E60 welds subjected to an axial force, a shear force, and a bending moment
about the z axis. The location of the hole in each bracket has the same relative dimensions for each problem. Use the brackets shown below. The dimension L is the specified length and not the effective length. Use a safety
factor of N = 3.0 for each problem. This group of problems is best solved by
developing a spreadsheet that incorporates the qx equation in (12.32) and the
qy equation in (12.7). Calculate the force and moment components from the
input data for the applied load and angle, which is always less than 90.
There is a single bracket in each case.
x
P
P
y
z
385
PROBLEMS
12.6 The weld length and leg dimension as well as information on the type
of bracket and applied load are presented in the table below. Determine whether the weld is adequate.
Problem
Bracket
(a)
(b)
(c)
(d)
(a)
(a)
(b)
(b)
Problem
Bracket
(a)
(b)
(c)
(d)
(a)
(a)
(b)
(b)
USCS Units
w, in
L, in
0.1875
0.2500
0.2500
0.1875
SI Units
w, mm
P, kips
7.00
6.00
6.00
6.50
6.83
7.45
6.92
7.80
30
38
45
62
L, mm
P, kN
180
200
150
180
31.2
41.2
29.4
31.2
35
28
51
65
5
6
5
4
12.7 Calculate the leg dimension w for the weld length and loading information presented in the table below. Use an E60 rod and a safety factor of N = 3.0. The leg dimension should increase in 1 mm or 1/16
inch increments. The ratio QR/Qall should be greater than 0.80. The solution procedure is trial and error. One procedure is to assume the full
length of the weld is the effective length and calculate the dimension
w. Select a standard dimension w and calculate the shear flow ratio
using the correct effective length.
Problem
(a)
(b)
(c)
(d)
Problem
(a)
(b)
(c)
(d)
USCS Units
Bracket
L, in
(a)
(a)
(b)
(b)
Bracket
(a)
(a)
(b)
(b)
5.50
6.75
5.00
7.00
SI Units
L, mm
180
170
140
150
P, kips
8.34
9.56
7.83
10.3
55
20
70
40
P, kN
38.6
31.6
42.3
34.3
42
24
64
35
386
12.8 The brackets in this problem are welded to the side of a member using
an E60 rod. The welds are subjected to two shear forces and a twisting moment about the x axis. The location of the hole in each bracket
has the same relative dimensions for each problem. The dimension for
a is the specified length and not the effective length. The effective
length for b is the full length. Use a safety factor of N = 3.0 for each
problem. This group of problems is best solved by developing a
spreadsheet that incorporates equations (12.16), (12.32), and (12.36).
The force and moment components should be calculated from input
data for the applied load and angle which is always less than 90. The
weld length b and the leg dimension w as well as information on the
type of bracket and applied load are presented in the table below. Determine whether the weld is adequate. Use the value a = 1.5 inch or a
= 40 mm for all of the problems. The applied load is supported by
two brackets in each case.
P
x
y
3 in 75 mm
3 in 75 mm
40
1.5
P12.8(a)
P12.8(b)
USCS Units
Problem
(a)
(b)
(c)
(d)
Bracket
(a)
(a)
(b)
(b)
w, in
0.1875
0.2500
0.1875
0.2500
b, in
7.00
6.50
4.25
6.00
P, kips
13.6
15.2
11.9
15.8
30
38
62
33
b, mm
180
200
160
200
P, kN
57.2
82.4
58.8
90.0
35
28
51
24
SI Units
Problem
(a)
(b)
(c)
(d)
Bracket
(a)
(a)
(b)
(b)
w, mm
5
6
5
6