DESIGN OF MACHINE

ELEMENTS – I
DESIGN OF WELDED JOINTS
21ME52
TYPES
WELDED JOINTS

Dr. Ramesh S Sharma

 Introduction
• Mechanical joints or fasteners are used for
making connections between different
elements of machine or structure.
• A machine or a structure is made of a large
number of parts and they need be joined
suitably for the machine to operate
satisfactorily.
• In manufacturing industries, joining of two
or more components is necessary for
assembly purposes.
• Joining makes the production system more
reliable, efficient and profitable.

Dr. Ramesh S Sharma

 • In fact, joining can be defined as one of the
manufacturing processes by which two or
more solid components can be assembled
together.
Types of joints Mechanical joints are broadly
classified into following two categories:
1. Permanent joints
• Permanent joints cannot be easily
disassembled without damaging the
connecting elements.
• Different types of permanent joints are
welded joints, brazed joints, soldered joints,
adhesive joints, riveted joints and interference
joints.
Dr. Ramesh S Sharma
2. Temporary or detachable joints
• Temporary joints can be easily
disassembled without damaging the
connecting elements.
• Different types of detachable joints are
threaded joints, pin joints, cotter & knuckle
joints, key joints and bolts & nuts.

Dr. Ramesh S Sharma

Dr. Ramesh S Sharma
 Types of permanent Fasteners

Components held by mechanical

force
a) Riveted Joints
b) Press-fitted or Interference
joints
Components held by molecular
force
a) Welded Joints
b) Soldered Joints
c) Glued or Adhesive Joints
Dr. Ramesh S Sharma
 WELDED JOINTS
• Welding is a process of joining similar metals by the
application of heat and with or without the application
of pressure and the filler material.
• Welding can be used as a substitute for a riveted joint.
Also a welded structure can be an alternative to casting
or forging.
• Welding is a very commonly used permanent joining
process. Due to great advancement in welding
technology, it has secured a prominent place in
manufacturing machine components.

Dr. Ramesh S Sharma

 Advantages of welding
1. Compared to other type of joints, the welded joint has higher
efficiency. An efficiency > 95 % can be easily achieved.
2. Since the added material is minimum, the joint has lighter weight.
3. Welded joints are less expensive. & have smooth appearances.
4. Due to flexibility in the welding procedure, alteration and
addition are possible.
5. It is Forming a joint in difficult locations is possible through
welding.
Some typically welded machine components are listed below;
Pressure vessels, steel structures, Flanges welded to shafts and
axles, Crank shafts, Gear housing, Machine frames and bases, etc.
Dr. Ramesh S Sharma
Advantages of Riveting and Welding
Disadvantages of Riveting and Welding
 Strength of welded joints:
Adequate care must be taken to enhance strength of the welded joint
which gets affected mainly by the following factors.
(i) Crack initiation: it is possible that cracks form while cooling a melted
metal.
(ii) Residual stresses: due to inhomogeneous heating of the base metals,
residual stresses may exist upon cooling.
(iii) Metallurgical transformation: in heat affected zone (HAZ)
metallurgical properties may change leading to weakening of the joint.
(iv) Defects: of various kinds like incomplete penetration, porosity, slag
inclusion which affect the strength of a welded joint.
(v) Stress concentration: abrupt change in the geometry after welding may
introduce stress concentration in the structure. 4
 Types of welded joints:
Welded joints are primarily of two kinds
a) Lap or fillet joint: obtained by overlapping the plates and welding their
edges. The fillet joints may be single transverse fillet, double transverse
fillet or parallel fillet joints.

5
Combined Transverse & Parallel Fillet weld

6
(b) Butt joints: formed by placing the plates edge to edge and welding them.
Grooves are sometimes cut (for thick plates) on the edges before welding.
According to the shape of the grooves, the butt joints may be of different types
such as, Square butt joint Single V-butt joint, double V-butt joint, etc.

7
There are other types of welded joints, for example,
• Corner joint
• Edge or seal joint
• T-joint

8
 Stresses in Welded Joints

For parallel fillet welds, shear stress is induced when load acts parallel to the weldment
P
= =
P
h cos 450 * l h * 0.707 *l

For transverse fillet welds, tensile stress is induced when load acts perpendicular to the
weldment
P
= =
P
h cos 450 * l h *0.707 * l
9
Problem 1: A rectangular plate 60mm wide, 12 mm
thick is welded to a support as shown in fig below.
Find the length of the welds required if the allowable
tensile stress is 90 MPa for the weld.

60mm
L F = 30kN

10
Given Data: P = 30kN = 30*103N;  = 90MPa; b=12mm
To find: L = ? (Length of the weld)
Sol. Assuming size of the weld = thickness of plate
i.e., h = b = 12mm
From the fig, it is evident the joint is double
transverse fillet joint, hence from table 6.1 / page 92
We have for double transverse fillet weld joint in
tension;
1.414𝑃
𝝈=
(ℎ1 + ℎ2 )𝐿
𝟏.𝟒𝟏𝟒∗𝟑𝟎∗𝟏𝟎𝟎𝟎
𝟗𝟎 = (𝟏𝟐+𝟏𝟐)∗𝑳
; (here h1 = h2 = 12mm)

Solving for ‘L’ we get L = 19.63 mm 20mm  Ans

Add 5mm for start and end of the weld
i.e., L = 20 + 5 = 25mm
Problem 2: For a bracket loaded as shown in fig
below; find the load carrying capacity taking size
of weld as 10mm and allowable stress for weld
joint is 120 MPa.

45 P
P

DESIGN OF WELDED JOINTS

(Page No 70, Mahadevan DDHB )
Given Data:  = 120MPa; h=10mm; L = 45mm
To find: P = ? (Load Carrying Capacity of the weld)
From table 6.1 / page 92
We have for double transverse fillet weld joint in
tension;
1.414𝑃
𝝈=
(ℎ1 + ℎ2 )𝐿
𝟏.𝟒𝟏𝟒∗P
𝟏𝟐𝟎 = (
𝟏𝟎+𝟏𝟎)∗45

Solving for ‘P’ we get P = 76.38 kN  Ans

Problem #3
Two plates welded by means of parallel fillet weld as
shown in fig below. The thickness of the plates is
10mm. Find the length of welds to sustain a steady
tensile load of 90kN. Assume mild steel bare
electrodes.
Given Data: h = 10mm; F = 90 *103N;
To Find: L = ?
From table 6.4 / page 94; for mild steel Bare
electrodes and fillet welds, therefore
all = 90 MPa
𝟎.𝟕𝟎𝟕𝑷
Also, 𝝈 = --------- eqn 6.2(c) / Page 90
𝒉𝑳
𝟎.𝟕𝟎𝟕∗𝟗𝟎∗𝟏𝟎𝟑
𝟗𝟎 =
𝟏𝟎∗𝑳
L = 70.7 mm  72 mm
Add 5mm for starting and ending of weld
 L = 72 + 5 = 77mm  Ans
Problem #4
A plate of 12 mm thick and 50mm wide carries a
static tensile load of 65kN and this plate is welded to
a plate by a parallel fillet weld as shown in fig below.
Determine the length of each weld using shielded arc
welds of 5 x 5 mm weld size.
Given Data: F = 65 *103N; weld size – 5 x 5 mm
To Find: L = ?
Sol. For weld size of 5 x 5; parallel weld shielded arc
We have from table 6.6b / page 95;
Fl – Static load/linear mm of weld = 275 N
Also, Fl = F/2L (to be remembered)
275 = (65*103) / (2*L)
L = 118.18mm  120mm
Add 5mm for starting and ending of weld
 L = 120 + 5 = 125mm  Ans
Problem # 5
A static load F = 300kN is to be supported by steel
plates welded as shown in the fig below by shielded
arc welds with coated electrodes
(a) Assuming 12mm thick plates are to be used,
determine the width of the plates to be specified.
(b) Determine the maximum stress in the plates and
Factor of safety?

F L F

F
F
 Given Data: F = 300 * 103 N; h = 12mm;
To find: (i) width of the plate = ?
(ii) Maximum Stress (max) in the plate = ?
(iii) FOS =?
Solution:
(a) Width of plate:
From the fig, assuming size of weld = thickness of plate
i.e., weld size = h = 12 x 12mm
Again from table 6.6 (c)/page 95, for weld size of 12x12
We have for normal weld & shield arc, Fl = 825N
(Allowable static load per linear mm of weld, N)
 Fl = F/2L; 825= (300 * 103) / 2 L;  L = 181.2  182 mm
Add 5mm, hence L = 182 + 5 = 187mm
From diagram, it is evident that width of the plate
length of the weld,  w = width = 187mm  1st Ans

(b) Maximum normal stress induced

𝟎.𝟕𝟎𝟕𝑷
𝝈= ----- 6.2 (b) /page 90
𝒉𝑳
𝟎.𝟕𝟎𝟕∗𝟑𝟎𝟎∗𝟏𝟎𝟑
= = 𝟗𝟒. 𝟓 𝑴𝑷𝒂  2nd Ans
𝟏𝟐∗𝟏𝟖𝟕

(c) Factor of safety

From table 6.2/page 94; for coated electrode
maximum yield stress = 380 N/mm2
FOS = y/max(all)
= 380 / 94.5 = 4.02
 Problem # 6
Two plates of 25mm thick are welded together by
means of a reinforced butt weld and subjected to
axial force of 100kN as shown in fig. Size of the weld
can be taken as 25mm and the permissible tensile
stress is 100 N/mm2, determine the length of the
weld required.

F F

Given Data: h = 25mm; F = 100 * 103N;  = 100 MPa

To Find: L = ?
Sol: From table 6.1 /page 92; we have for double
v-grooved butt weld in tension;
 𝑷
𝝈=
(𝒉𝟏 + 𝒉𝟐 )𝑳
Here h1 = h2 = h =25mm
100 ∗ 103
𝟏𝟎𝟎 =
(25 + 25) ∗ 𝐿
Solving for ‘L’ we get L = 20mm
Add 5mm for starting and ending of weld
Therefore, L = 20 + 5 = 25mm  Ans
Problem # 7
A mild steel plate 15mm thickness is welded to another
plate by two parallel welds to carry a load of 50kN.
Determine the length of weld required, when
(i) Load is static
(ii) Load is dynamic, consider SCF
Assume bare electrodes and steady loads
Given Data: h = 15mm; F = 50 * 103N;
To Find: i) L = ? (when load is static)
ii) L = ? (when load is dynamic)
Sol: Case 1: Static Load
From table 6.4 / page 94; for mild steel electrodes
assume Bare electrode and fillet welds, therefore
 = 90 MPa
 𝟎.𝟕𝟎𝟕𝑷
Also, 𝝈 = --------- eqn 6.2(c) / Page 90
𝒉𝑳
𝟎.𝟕𝟎𝟕∗𝟓𝟎∗𝟏𝟎𝟑
𝟗𝟎 =
𝟏𝟓∗𝑳
L = 26.18 mm  28 mm
Add 5mm for starting and ending of weld
 L = 28 + 5 = 33mm  Ans
Case 2: Dynamic Load
𝝈𝒎𝒂𝒙
For Dynamic load: 𝝈 =
𝑺𝑪𝑭

From table 6.3 / page 94; SCF = 2.7; for end of

longitudinal fillet weld
𝝈𝒎𝒂𝒙 𝟗𝟎
𝝈= = = 𝟑𝟑. 𝟑𝟑 𝑴𝑷𝒂
𝑺𝑪𝑭 𝟐. 𝟕
 𝟎.𝟕𝟎𝟕𝑷 𝟎.𝟕𝟎𝟕∗𝟓𝟎∗𝟏𝟎𝟑
Also, 𝝈 = = 𝟑𝟑. 𝟑𝟑 =
𝒉𝑳 𝟏𝟓∗𝑳

L = 70.7  72 mm
Add 5mm for starting and ending of weld
 L = 72 + 5 = 77mm  Ans

Problem #8 A plate 100 mm wide and 10 mm thick

is to be welded to another plate by means of
double parallel fillets. The plates are subjected to
a static load of 80 kN. Find the length of weld if the
permissible shear stress in the weld does not
exceed 55 MPa.
Given Data: h = 10mm; F = 80 *103N; w =100mm;
τ = 55 MPa = 55 N/mm2
To Find: L = ?
Sol. Let L =Length of weld, and
w = Size of weld = Plate thickness = 10 mm
We know that maximum load, which the plates can
carry for double parallel fillet weld (P),
 𝑷
𝝉= (to be remembered)
𝟏.𝟒𝟏𝟒∗𝒉∗𝑳
80 × 103 = 1.414 × h × L × τ
= 1.414 × 10 × l × 55 = 778 L
∴ L = 80 × 103 / 778 = 103 mm
Adding 5 mm for starting and stopping of weld run,
we have L = 103 + 5 = 108 mm Ans
 ECCENTRICALLY LOADED WELDED JOINTS :
(TYPE I - Welds subjected to torsion)
F = Eccentric load on the weld
c.g = Center of gravity of weld
mx = Distance of c.g from the top of the weld
ny = Distance of c.g from the left of the weld
x & y horizontal & vertical distances of cg from right top corner
r = Distance of c.g from the right top corner
 ' = Primary shear stress,  " = Secondary shear stress
 = Allowable shear stress in the weld
Design procedure for Welded Joint :
1L)ocate the cg of the weld :
Refer T 6.7, page 96 for mx & ny equations
and find 'e ' using the above value of ny
2F
) ind the distance 'r' & angle :
x
r = x + y , cos =
2 2
r
P
3P
) rimary shear stress : ' = Eq 6.3a.Page91
hcos 450  l
F
 ' = where throat thickness t = h cos 450 & h = size of weld
t l
P e r
4Secondary she ar stress : '' =
2J
where J=Polar moment of inertia of weld geometry from
T 6.7, column 3, Page 96.
Design procedure for Welded Joint :
5M
) aximum shear stress :
 max =  '2 + ' 2 + 2 ' "cos Eq 6.3c, Page91
6S
) ize of the w eld :
Equating  max to the max allowable shear stress, find 't'.
ht
Also h = cos45
Problem # 1
The size of the weld for a bracket welded as shown in
fig below is 8mm. The fillet weld is made using bare
electrode. Calculate the maximum steady load that the
bracket can support without failure.
P P
250 mm
n/2 e

m/2 
r

100 mm O

80 mm

Fig – a Fig – b
 Given Data: Fillet weld size = h = 8mm; m=100mm;
n=80mm
e = 250 + n/2 = 250 + 80/2 = 290 mm
For the fillet weld using bare electrode with steady
loads, from table 6.4 / page 94;
we have max = 78N/mm2
i. Primary shear stress ( )
′ 𝑷
𝝉 = --------- eqn. 6.3(a) /pg 91
(𝒉𝒄𝒐𝒔𝟒𝟓°)𝑳
𝑷 𝑷 𝑷
=
(𝟖∗𝟎.𝟕𝟎𝟕∗𝟏𝟔𝟎)
= 𝟗𝟎𝟒.𝟗𝟔
≈ 𝟗𝟎𝟓 ------- (1)

ii. Secondary shear stress ( ’)

′′ 𝑷𝒆√𝒎𝟐 +𝒏𝟐
𝝉 = ----- eqn. 6.3(b) /pg 91
𝟐𝑱
 𝒉𝒕 𝒏(𝟑𝒎𝟐 +𝒏𝟐 )
But 𝑱 = -------- table 6.7 /page 96
𝟔
Where ht –throat thickness = hcos45
= 8 cos45 = 8*0.707
𝟖∗𝟎.𝟕𝟎𝟕∗𝟖𝟎(𝟑∗𝟏𝟎𝟎𝟐 + 𝟖𝟎𝟐 )
= =2745 * 103 mm4
𝟔
𝑷∗𝟐𝟗𝟎√𝟏𝟎𝟎𝟐 +𝟖𝟎𝟐 𝑷
 𝝉′′ =
𝟐∗𝟐𝟕𝟒𝟓∗𝟏𝟎𝟑
=
𝟏𝟒𝟕.𝟖𝟑
------ (2)
𝒏 𝟖𝟎
Also, 𝒄𝒐𝒔𝜽 = = = 𝟎. 𝟔𝟐𝟓
√𝒎𝟐 +𝒏𝟐 √𝟏𝟎𝟎𝟐 +𝟖𝟎𝟐
From eqn (1) and eqn (2);
𝝉𝒎𝒂𝒙 = √(𝝉′)𝟐 + (𝝉′′)𝟐 + 𝟐𝝉′𝝉′′𝒄𝒐𝒔𝜽 ---- eqn6.3c /pg91
𝑷 𝟐 𝑷 𝟐 𝑷 𝑷
𝟕𝟖 = √( ) +( ) +𝟐∗ ∗ ∗ 𝟎. 𝟔𝟐𝟓
𝟗𝟎𝟓 𝟏𝟒𝟕.𝟖𝟑 𝟗𝟎𝟓 𝟏𝟒𝟕.𝟖𝟑

Solving for ‘P’ we get P = 10393.4N or P = 10.4kN  Ans

Problem # 2
A bracket supporting a load of 3kN is welded to a
vertical member by four fillet welds as shown in fig
below. Calculate the size of the weld, if the stress at
throat section not to exceed 85MPa.

P = 3kN
100 mm e
n

m
70 mm
o

50 mm n
 Given Data: F = 3000N; max = 85N/mm2; m= 70mm;
n=50mm
To find: size of the weld: h = ?
Sol. Length of the weld = 2m + 2n = 2*70 + 2*50 = 240mm
Eccentricity = e = 100 + n/2 = 100 + 50/2 = 125 mm
i. Primary shear stress ( )
′ 𝑷
𝝉 = --------- eqn. 6.3(a) /pg 91
(𝒉𝒄𝒐𝒔𝟒𝟓°)𝑳
𝟑𝟎𝟎𝟎 𝟏𝟕.𝟔𝟖
=
(𝒉∗𝟎.𝟕𝟎𝟕∗𝟐𝟒𝟎)
= 𝒉
------- (1)
ii. Secondary shear stress ( ’)
′′ 𝑷𝒆√𝒎𝟐 +𝒏𝟐
𝝉 = ----- eqn. 6.3(b) /pg 91
𝟐𝑱
𝒉𝒕 (𝒏+𝒎)𝟑
Where 𝑱 = --------- from table 6.7 /page 97
𝟔
𝒉𝒄𝒐𝒔𝟒𝟓°(𝟓𝟎+𝟕𝟎)𝟑
= = 𝟐𝟎𝟑𝟔𝟒𝟔. 𝟕𝟓 𝒉 (ht =hcos45)
𝟔
 𝟑𝟎𝟎𝟎∗𝟏𝟐𝟓√𝟕𝟎𝟐 +𝟓𝟎𝟐 𝟕𝟗.𝟐
 ′′
𝝉 = = ------ (2)
𝟐∗𝟐𝟎𝟑𝟔𝟒𝟔.𝟕𝟓∗𝐡 𝐡

𝒏 𝟓𝟎
Also, 𝒄𝒐𝒔𝜽 = = = 𝟎. 𝟓𝟖𝟏
√𝒎𝟐 +𝒏𝟐 √𝟓𝟎𝟐 +𝟕𝟎𝟐
From eqn (1) and eqn (2);
𝝉𝒎𝒂𝒙 = √(𝝉′)𝟐 + (𝝉′′)𝟐 + 𝟐𝝉′𝝉′′𝒄𝒐𝒔𝜽 ---- eqn6.3c /pg91
𝟏𝟕.𝟔𝟖 𝟐 𝟕𝟗.𝟐 𝟐 𝟏𝟕.𝟔𝟖 𝟕𝟗.𝟐
𝟖𝟓 = √( ) +( ) +𝟐∗ ∗ ∗ 𝟎. 𝟓𝟖𝟏
𝒉 𝒉 𝒉 𝒉

Solving for ‘h’ we get

h = 1.066mm
From table 6.6(b) / page 95; Std size available is 3 x 3 mm Ans
Problem # 3
Find the size of the weld required for a bracket
supporting a load of 20kN shown in fig below, if the
stress at throat section not to exceed 70MPa.
ny x
20kN
e

100

nx y
r
80
c.g
.

50
 Given Data: P = 20*103kN; max = 70MPa; m = 80mm;
n = 50mm
To find: h = ? (size of the weld)
Sol: Total Length of weld: L = 2*50 + 80 = 180mm
Step 1: To locate C.G.
𝒎 𝟖𝟎
𝒏𝒙 = = = 𝟒𝟎 𝒎𝒎 (𝑺𝒚𝒎𝒎𝒆𝒕𝒓𝒊𝒄)
𝟐 𝟐
𝟐
𝒏 𝟓𝟎𝟐
𝒏𝒚 = = = 𝟗. 𝟔𝟏𝟓𝒎𝒎
𝟐(𝒏 + 𝒎) 𝟐 ∗ 𝟓𝟎 + 𝟐 ∗ 𝟖𝟎
Step 2:
x = 50 – ny = 50 – 9.615 = 40.38mm
y = nx = 40mm
𝒓 = √𝒙𝟐 + 𝒚𝟐 =√𝟒𝟎. 𝟒𝟖𝟐 + 𝟒𝟎𝟐 = 𝟓𝟔. 𝟖𝟒 𝒎𝒎
e = 100 + x = 100 + 40.38 = 140.38mm
 𝒙 𝟒𝟎.𝟑𝟖
𝒄𝒐𝒔𝜽 = = = 𝟎. 𝟕𝟏
𝒓 𝟓𝟔.𝟖𝟒

Step 3: Primary shear stress ( )

′ 𝑷
𝝉 = --------- eqn. 6.3(a) /pg 91
(𝒉𝒄𝒐𝒔𝟒𝟓°)𝑳
𝟑
𝟐𝟎∗𝟏𝟎 𝟏𝟏𝟏.𝟏𝟏
=
(𝒉𝒕 ∗𝟏𝟖𝟎)
= 𝒉𝒕
------- (1)
(Because ht = hcos45)
Step 4: Secondary shear stress ( )
′′ 𝑷𝒆√𝒎𝟐 +𝒏𝟐
𝝉 = ----- eqn. 6.3(b) /pg 91
𝟐𝑱
𝟐𝟎∗𝟏𝟎𝟑 ∗𝟏𝟒𝟎.𝟑𝟖√𝟖𝟎𝟐 +𝟓𝟎𝟐
=
𝟐𝑱
(𝟐𝒏+𝒎)𝟑 𝒏𝟐 (𝒏+𝒎)𝟐
Where 𝑱 = 𝒉𝒕 { − (𝟐𝒏+𝒎)
} ------ from table 6.7 /page 96
𝟏𝟐
 (𝟐 ∗ 𝟓𝟎 + 𝟖𝟎)𝟑 𝟓𝟎𝟐 (𝟓𝟎 + 𝟖𝟎)𝟐
= 𝒉𝒕 { − }
𝟏𝟐 (𝟐 ∗ 𝟓𝟎 + 𝟖𝟎)
𝑱 = 𝟐𝟓𝟏𝟐𝟕𝟕. 𝟕𝟕𝒉𝒕
′′ 𝟐𝟎∗𝟏𝟎𝟑 ∗𝟏𝟒𝟎.𝟑𝟖√𝟖𝟎𝟐 +𝟓𝟎𝟐
 𝝉 =
𝟐∗𝟐𝟓𝟏𝟐𝟕𝟕.𝟕𝟕𝒉𝒕
On simplification, we get
′′ 𝟓𝟏𝟏.𝟎𝟓
𝝉 = ----------- (2)
𝒉𝒕
Step 4: Resultant shear stress (max)
𝝉𝒎𝒂𝒙 = √(𝝉′)𝟐 + (𝝉′′)𝟐 + 𝟐𝝉′𝝉′′𝒄𝒐𝒔𝜽 ---- eqn6.3c /pg91
𝟏𝟏𝟏.𝟏𝟏 𝟐 𝟓𝟏𝟏.𝟎𝟓 𝟐 𝟏𝟏𝟏.𝟏𝟏 𝟓𝟏𝟏.𝟎𝟓
70 = √( ) +( ) +𝟐∗ ∗ ∗ 𝟎. 𝟕𝟏
𝒉𝒕 𝒉𝒕 𝒉𝒕 𝒉𝒕
Solving for ‘ ht’ we get ht = 8.44 mm
But ht = h cos45➔ i.e., 8.44 = h * 0.707
 h = 11.9mm  12 mm; standard size 12 x 12
Special cases of Fillet Welds
Case 1: Circular fillet weld subjected to torsion:
Consider a circular rod connected to a rigid plate by a
fillet weld as shown in fig
Let D – diameter of the rod
R – Radius of the rod
T – Torque acting of the rod
h – Size (or leg) of the weld
ht – throat thickness
J - Polar moment of inertia
of the weld section
= (htD3)/4
We know that shear stress for the material is given by
𝑻. 𝒓 𝑻 ∗ 𝑫/𝟐
𝝉= =
𝑱 𝑱
𝑻∗𝑫/𝟐 𝟐𝑻
= 𝟑 = 𝟐
𝝅𝒉𝒕 𝑫 /𝟒 𝝅𝒉𝒕 𝑫
This shear stress occurs in a horizontal plane along a
leg of the fillet weld. The maximum shear occurs
which is inclined at 45 to the horizontal plane.
Therefore, length of the throat = ht = h cos45= 0.707h
And maximum shear stress is given by
𝟐𝑻 𝟐.𝟖𝟑𝑻
𝝉𝒎𝒂𝒙 = = ------- table 6.1 / page 93
𝝅∗𝟎.𝟕𝟎𝟕∗𝒉∗𝑫𝟐 𝝅𝒉𝑫𝟐
Case 2: Circular fillet weld subjected to Bending Moment:
Consider a circular rod connected to a rigid plate by a
fillet weld as shown in fig

Let D – diameter of the rod

M – Bending Moment
acting on the rod
h – size (or leg) of the weld
ht – throat thickness
Z – Section modulus
of the weld section
= (htD2)/4
We know that bending stress occurs in a horizontal
plane along a leg of the fillet weld. The maximum
bending stress occurs on the throat of the weld which
is inclined at 45 to the horizontal plane.
 Length of the throat, ht = hcos45 = 0.707h and
maximum bending stress is given by

𝟒𝑴 𝟓.𝟔𝟔𝑴
𝝈𝒎𝒂𝒙 = = ---- table 6.1 / page 93
𝝅∗𝟎.𝟕𝟎𝟕∗𝒉∗𝑫𝟐 𝝅𝒉𝑫𝟐
Case 3: Long fillet weld subjected to Torsion:
Consider a vertical plate attached to a horizontal plate by
two identical fillet welds as shown in fig
Let T – torque acting on the
vertical plate
L – Length of the weld
h – size (or leg) of the weld
ht – throat thickness
J – Polar Moment of
inertia of the weld section
𝒕∗𝑳𝟑 𝒕∗𝑳𝟑
=𝟐∗ = (⸪of both sides weld)
𝟏𝟐 𝟔
The effect of the applied torque is to rotate the vertical
plate about Z-axis through its mid-point. This rotation is
resisted by shearing stresses developed between two
fillet welds and the horizontal plate.
𝑻∗𝑳/𝟐 𝟑𝑻
Shear stress = 𝝉 = =
𝒕∗𝑳𝟑 /𝟔 𝒕∗𝑳𝟐
The maximum shear stress occurs at the throat and is
given by
𝟑𝑻 𝟒.𝟐𝟒𝟐𝑻
𝝉𝒎𝒂𝒙 = = ----- Table 6.1 / page 93
𝟎.𝟕𝟎𝟕𝒉∗𝑳𝟐 𝒉∗𝑳𝟐
Problem # 1
A 50 mm diameter solid shaft is welded to a flat plate
by 10 mm fillet weld as shown in Fig. below. Find the
maximum torque that the welded joint can sustain if
the maximum shear stress intensity in the weld
material is not to exceed 80 MPa.
Given Data: D = 50mm; h = 10mm;
max = 80 MPa;
We know that maximum shear
stress (max) is given by
𝟐. 𝟖𝟑𝑻 𝟐. 𝟖𝟑𝑻 𝟐. 𝟖𝟑𝑻
𝝉𝒎𝒂𝒙 = 𝟐
= 𝟐
=
𝝅𝒉𝑫 𝝅 ∗ 𝟏𝟎 ∗ 𝟓𝟎 𝟕𝟖𝟓𝟓𝟎
2.83∗𝑇
i.e., 80 = → 𝑻 = 𝟐. 𝟐𝟐 ∗ 𝟏𝟎𝟔 𝑵 − 𝒎𝒎
78550
 Problem # 2
A plate 1 m long, 60 mm thick is welded to another
plate at right angles to each other by 15 mm fillet
weld, as shown in Fig below. Find the maximum torque
that the welded joint can sustain if the permissible
shear stress intensity in the weld material is not to
exceed 80 MPa.
Given Data: L = 1m = 1000mm; h = 15mm;
max = 80 MPa; thickness of plate = 60mm
Sol. We know that maximum shear
stress is given by
𝟒. 𝟐𝟒𝟐𝑻
𝝉𝒎𝒂𝒙 = 𝟐
𝟒.𝟐𝟒𝟐∗𝑻
𝒉 ∗ 𝑳
i.e., 𝟖𝟎 = =>> 𝑻 = 𝟐𝟖𝟑 ∗ 𝟏𝟎𝟔 𝑵 − 𝒎𝒎
𝟏𝟓∗𝟏𝟎𝟎𝟎
 Problem 1
Determine the size of the weld for the joint shown in fig
taking the allowable shear stress as 62 MPa.
60 KN
400 900

600

13
Data : F = 60 KN.
From Table 6.7, page 74, distances m = 600 mm & n = 400 mm
ny e

400 900 60 KN

mx r
y  "
c.g x '
600

max

1L)ocation of c.g :
From Table 6.7, Page 74, for the geometry of weld shown in 5throw,
m2 6002 n2 4002
mx = = = 180 mm, ny = = = 80 mm
2(n + m) 2(400 + 600) 2(n + m) 2(400 + 600)
Dr P R Venkatesh, Mech Dept, RVCE,
Bangalore
 ) ind the distance 'r' & angle : 
2F
From fig, x = (n − ny ) = (400 − 80) = 320 mm &
y = mx = 180 mm  r = x2 + y2 = 3202 +1802 = 367.15 mm
x 320
Also cos = = = 0.872
r 367.15
Eccentricty of load from c.g, e = (x + 900) = (320 + 900) =1220 mm
F
) rimary shear stress : ' =
3P Eq 6.1.Page70
(b cos 45 )  l
0

F 60 103
 ' = = =
60
t  l t (400 + 600) t
F er
) econdary she ar stress : '' =
4S
J
where J=Polar moment of inertia of weld geometry from T 6.7, Page 74.
 (n + m)4 − 6n2m2 
For the given geometry of DrwP ReVlednk,atJesh,=MetchDept, RVCE, 
Bangalore 1 2 (n + m) 
4S
) econdary shear stress(contd...:)
'' = F  e  r 60 103
1220  367.15 493
= 6
=
J 54.5310 t t
5M
) aximum shear stress :
 max =  '2 + ' 2 + 2 ' "cos Eq 6.3, Page70
1
 62 = 602 + 4932 + 2 60 493 0.872
t
Throat thickness of the weld t = 8.8 mm
6S
) ize of the wel d : As t = b cos 450,
t
size of the weld b = =
8.8 13 mm
0.707 0.707
 (TYPE II - Welds subjected to Bending )
Design procedure for Welded Joint subjected to bending :
F
1S
) hear stress :  = Eq 6.1.Page70
b cos 45  l
0

F
= where throat thickness t = b cos 450 &
t l
b = size of the weld
Fe
2B
) ending stress : =
z
where Z=Section modulus of weld from T 6.7, column 2, Page 74.
(If two equations are given for z, calculate both & take least value)


2

3M
) aximum shear stress :  max =   +  2
2
Equating  max to the max allowable shear stress, find 't'.
t
Also b = . (If t is given, find safe load F)
0.707
 Problem 1
Determine the size of the weld for the joint shown in fig
taking the allowable shear stress as 80 MPa.

25 KN
500 mm

150

100

18
 (TYPE II - Welds subjected to Bending)
Design procedure for Welded Joint subjected to bending :
F
) hear stres s :  =
1S Eq 6.1.Page70
b cos 45  l
0

Here, l = 2(100 +150) = 500 mm

2510 50
=3 =
t
t  500
Fe
) end ing stress :  =
2B
z
where Z=Section modulus of weld from T 6.7, column 2, Page 74A.
 m2 
For the given geometry, Z = t  nm + ,
 3 
Here, n = 100 mm, m = 150 mm.
3
  3

150
 Z = t 100150 + 2 22500 t   = 2510
 500
=
22500t 5
5
5
.
5
6
t =
 
 (TYPE II - Welds subjected to Bending)

2

3M
) aximum shear str ess :  max =   +  2
2
1 2
 80 =  555.56 
  + 502
 t = 3.53 mm
t  2 
Also b = t = 3.53 = 5 mm
0.707 0.707