Professional Documents
Culture Documents
Dr. S. RAVIRAJ
Assistant Professor of Civil Engineering Sri Jayachamarajendra College of Engineering, Mysore 06
1.0 INTRODUCTION Welding is the process to unite various pieces of metal by creating a strong metallurgical bond. Bond is achieved by heat or pressure or both. Welding is the most efficient and direct way of connecting the metal pieces. Over many decades, different welding techniques have been developed to join metals.
2.0 TYPES OF WELDING Welding is generally performed by either electric or gas. Most of the welding is done using electric supply. Though gas welding is relatively cheaper, it is a slow process. Hence this method is generally used for repair and maintenance purposes.
2.1 Gas Welding It is also called as oxy-acetylene welding. Here the mixture of gases namely
acetylene and oxygen is burned at the tip of a torch, which produces a very hot flame. This heats the metal pieces for cutting and welding process. The features of a typical gas welding is shown in Fig. 1. 2.2 Arc Welding
Fig. 1 Gas Welding
Arc welding is used in most of the structural welding operations. Here, electric energy which is used as the heat source is produced by electric arc. The base metal and welding rod (or electrode) are heated to fusion tempe rature by the electric arc. The typical arc welding equipments and accessories are shown in Fig. 2. The welding rod is connected to one terminal of the current source and the object to be welded is connected to the other terminal. The temperature in the region of welding ranges from 3300 C to 5500 C.
o o
Metal
Arc
Welding
This is the most popular method of arc welding. Heating is done by means of electric arc between a coated electrode and the material being joined. If uncoated or bare wire electrodes are used, the molten metal gets exposed to atmosphere and combines chemically with oxygen and nitrogen and forms defective welds. The coating on the electrode forms a gaseous shield that helps to exclude oxygen and protects the molten metal from oxidation. The flux of the electrode coating, being lighter than molten metal, hardens at the surface of the weld. This can be removed by gentle tapping or by brushing. The typical features of shielded metal arc welding are shown in Fig. 3.
Fig. 3 Shielded metal arc welding The type of welding electrode used decides the weld properties like strength, ductility and corrosion resistance. The choice of electrode depends upon the type of metal being welded, the amount of material to be added, and the position of work.
There are two types of electrodes: Lightly coated electrodes Heavily coated electrodes Heavily coated electrodes are used in structural welding. These electrodes result in welds that are stronger, more corrosion resistant, and more ductile (compared to lightly coated electrodes). Usually the SMAW process is either automatic or semi-automatic. The main advantage of SMAW is that high quality welds can be made rapidly at a low cost. The grade and properties of electrodes are listed in Table 1 of IS 800 : 2007 which is as per IS 814 : 2004. 3.0 ADVANTAGES OF WELDING There are many advantages of welding. Some of the important ones are as follows. 1. Welded joints are aesthetical to look when compared to bolted joints.
2. Welded joints are more rigid than bolted joints. Hence the material at various sections are utilized more efficiently to resist stresses than that of less rigid connections. 3. Welding does not require driving of holes. This reduces the cost incurred for drilling. Hence, while computing the tensile strength of members, the net area remains the same as the gross area. 4. Welded joints are well suited for liquid and gas containing structures. 5. Welding offers the possibilities of fabricating new sections like castellated beams or creating complex joints in tubular truss.
4.0 DISADVANTAGES OF WELDING Some of the disadvantages of welding are; 1. Welding requires greater skill than bolting and hence requires highly skilled human resources. 2. Improper welding will distort the members and its alignment, and hence requires more concentration. 3. The inspection of weld joints is more difficult and cumbersome than bolted joints. 4. The process of welding may leave a higher residual stress in the material. 5. Welding equipment is more expensive and requires larger initial investment. 6. Welding at site is more difficult and also requires constant power supply.
1. Fillet welds 2. Groove welds 3. Slot welds, and 4. Plug welds Of these welds, fillet is used to a large extent. Groove welds are used to a lesser extent. However, slot and plug welds are rarely used.
5.1Fillet Welds
Fillet welds (Fig. 4A) are widely used due to their economy, ease of fabrication, and adoptability at site. They are approximately triangular in cross section (Fig. 4). These welds require less precision in fitting up two sections, due to the overlapping of pieces. They are adopted in field as well as in shop welding. It does not require any edge preparation and hence cheaper than groove welds. Fillet welds are assumed to fail in shear. They can be present on one side (single) or on both sides (double) of a member as shown in Table1 and Fig. 5.
Table 1 Single and double fillet welds
S IN GL E
DOUBLE
FILLET
5.2 GRO OVE WELDS In this type of weld, grooves are generally made in the base metal before welding and hence are called as groove weld. They are generally used to connect structural members aligned in the same plane, such as in butt joints. The details of a typical groove weld are shown in Fig. 6.
Some of the commonly used groove welds in butt joints are shown in Fig. 7.
The square groove weld is used to connect plates up to 8 mm thickness. They are also used in T-connections. The grooves have a slope of 30 and 60 with the vertical, which depend on the thickness of the plate and the welding operation. Partial penetration groove welds should not be used especially in fatigue situations. Root opening or gap (see Fig. 6) is provided for the electrode to access the base of the joint. The bevel angle (see openings is shown in Table 2.
Table 2 Root openings and bevel angle for groove weld Root openings 3 mm 6 mm 9 mm Bevel angle 60 45 30
O O O
Weld metal is more expensive than the base metal. Hence, the choice between single or double penetration depends on the availability of access on both sides, the thickness of plate to be welded, the type of welding equipment available and the position of weld.
When the plate thickness is more than 12 mm, the groove can be either double-bevel or double-V type. When the plate thickness is more than 40 mm, the groove can be either double - U or double - J type. For plates between 12 to 40 mm, the groove can be wither single-J and single-U type.
Groove welds are chosen in situations where the members need to transmit the full load of the members they join. Hence, the strength of welds should be more than or equal to the strength of the members they join. To ensure this, full penetration groove welds are used more frequently.
5.3 SLOT AND PLUG WELDS Slot and Plug welds (Fig. 8) are limitedly used to connect the steel members. They are generally used to complement the fillet welds in situations where it is not possible to provide sufficient length of fillet welds due to some constraints. These welds fail in shear. The extent of penetration of these welds into the parent metal is difficult to determine since it is difficult to inspect it. They are to be avoided when the members are subjected to tensile forces. The calculation of design strength of slot or plug welds are similar to that of fillet welds.
6.0WELDING POSITON The welding positions can be of four types, which are: Flat Overhead Vertical Horizontal - On the floor - Under the roof - On the wall - On the wall
Figure 9 shows the different weld positions which exist during welding operation.
7.0 TYPES OF JOINTS There are five basic types of common joints. They are Butt joint Lap joint T joint Corner joint, and Edge joint Each joint is suitable for a specific situation. The choice of the joint for a particular job depends on the size and shape of the members to be welded at the joint, the type of loading, area available for welding at the joint, and relative cost of various types of welds. 7.1 Butt Joint
Butt joints are used to join the ends of flat plates of nearly equal thickness. A typical butt joint is shown in Fig. 10. This joint avoids eccentric transfer of force at the connection. It is preferable to have full penetration of welds at the butt joints so that the joint is fully efficient. The size of connection is quite small and hence is very economical. It is aesthetical to look at. Face reinforcement (weld beyond the surface) is normally provided in Butt joints. This increases the efficiency of the joint and ensures that depth of weld is at least equal to the thickness of the plate.
Lap joints are easy to fit and join any two members. A typical lap joint is shown in Fig. 11. It is the most commonly used joint. It does not require any special preparation. Lap joints utilize fillet welds. They are well suited for shop and field welding. Lap joints can accommodate minor errors in fabrication and minor adjustment in length. The main advantage of lap joints is that it can join plates with different thicknesses without any difficulty (Fig. 12). The main disadvantage of this joint is that it introduces eccentric transfer of loads at the connection.
7.3 T Joints
A T-joint is usually used to fabricate built-up sections from simple members. A typical T-shaped joint is shown in Fig. 13. Some of the commonly used built-up shapes where T-joints are seen are I-sections, Plate girders, Hangers, Brackets, and Stiffeners. The members in the built-up sections are joined by means of fillet welds or groove welds.
7.4 Corner Joint Corner joints are normally seen in built - up rectangular box sections. A typical corner joint is shown in Fig. 14. They are generally seen at places which are subjected to high torsional moments.
Corner joints are seen in the built - up rectangular box sections. A typical corner joint is shown in Fig. 14. They are commonly seen at places which are subjected to high torsional moments.
Edge joints are generally not used in structural applications. They are used to keep two or more plates in position in a given plane. A typical edge joint is shown in Fig. 15.
8.0 WELD SYMBOL AND WELDING SYMBOL A weld symbol is a symbol which indicates the type of weld to be adopted to joint the metal pieces. However, a welding symbol is a concise way of describing all particular information related to the weld on drawings.
8.1 Weld Symbol Weld symbol is unique for each specific type of weld. Hence the weld symbol used is different for fillet, groove, plug, and slot welds.
8.1.1 Basic Weld Symbols The basic weld symbols for the commonly used welds are shown in Table 3.
Weld symbol is only a part of the information regarding the welding operation to be performed at a joint. As indicated in Table 3, whenever a weld symbol consists of both vertical and inclined legs, the vertical is always drawn towards the left side of the inclined line.
8.2 Welding Symbol The welding symbol contains all the information necessary in connection with a welding operation. It also includes the type of weld, where welds are to be located, the type of joint to be used, and the size and amount of weld metal to be deposited in the joint. The symbols used are standardized by the various codes of practice so that the entire information can be concisely represented in a drawing.
The basic welding symbol comprises of three parts, namely a reference line an arrow, and a tail
Apart from this there are also supplementary welding symbols to represent Dimensions and other data Supplementary symbols Finish symbols Specification, process or other reference
Reference Line The reference line is always drawn horizontally. It is mandatory and forms the foundation of a welding symbol. All information with respect to the welding process is to be indicated around this line.
Arrow The arrow line is present at one end of the reference line. It simply connects one end of the reference line to the joint or area to be welded. The direction of the arrow has no bearing on the significance of the reference line. Some of the possible types of arrows used in the welding symbol are shown in Fig. 17.
Tail The tail is shown on the other end (away from arrow end) of the reference line. It is not mandatory. The tail is used to specify a certain welding process. It is used only when necessary. It is used to mention some special characteristic of the weld like type of electrode, some type of reference or specification, welding or cutting process, procedures or other supplementary information. If additional information is not needed, then the tail will be omitted. The representation of tai with additional information is shown in Fig. 18.
The symbol indicates that one edge of a joint is to be beveled. The arrow should points towards the member to be beveled. Hence, the arrow should show a definite break so that the member to be beveled can be clearly identified.
Fig. 22 Bevel edge
The standard location of various elements of a welding symbol to be indicated in drawing is summarized below.
There are some supplementary weld symbols used in addition to the basic weld symbols which are indicated in section 8.1. These include Finish and contour symbols, All round weld, and Field or site weld which are shown in Table 4.
Table 4 Supplementary weld symbols
8.3.1 Finish and contour symbols Finish symbol shows the method of finish to be carried out to a weld. Generally, the finish of welding is either by chipping (C) or by machining (M) or by grinding (G). Contour symbols are used with weld symbols to show how the face of the weld is to be formed. The face of the weld will be either flat, convex or concave as shown in Table 4.
The all round symbol (Table 4) indicates that the welds are continued all around the joint. A typical all round weld and its representation is shown in Fig. 24.
The symbol used for field or site weld is a flag (Table 4). It points toward the tail of welding symbol. If no symbol is present, it indicates the weld as shop weld. A typical representation of field or site weld is shown in Fig. 25.
9.0 WELD D E F ECTS As mentioned earlier, welding requires greater skill so that the defects can be avoided. Some of the commonly observed defects in welds are; 1. Incomplete fusion 2. Incomplete penetration 3. Porosity 4. Undercutting 5. Inclusion of slag 6. Cracks 7. Lamellar tearing 1. Incomplete fusion
This occurs when the surfaces have not been cleaned properly, and are coated with oxides, mill scales, and other foreign materials. Insufficient current supplied by the welding equipment or high rate (speed) of welding can also lead to incomplete fusion. 2. Incomplete penetration Incomplete penetration can be due to improper grooves or unsuitable groove design made for the welding process. This can also be a result of the usage of large size electrodes, insufficient welding current, and excessive welding rates. 3. Porosity Improper welding techniques will result in air voids being entrapped in the molten metal during the cooling process resulting in porosity. Some of the common reasons are excessively high current, longer arc length, poor welding procedures, and careless use of back-strips. 4. Undercutting In case of groove welds, grooves are made at the edges of the base metal to accommodate the welding process. If the grooves are not completely filled with weld, it results in undercutting of the base metal (i.e., the thickness of the base metal will be less in that region). This may lead to places of stress concentrations during the process of force transfer and can be dangerous. Hence to eliminate undercutting, it is mandatory to have face reinforcement (welding over the surface of base metal) in all groove joints. 5. Inclusion of slag
Slag is formed from the coating of the electrodes which are used to shield the molten material from oxides during the cooling process. The slag is generally removed after the weld cools by either wire brushing or by gentle tapping. If the process of cooling is done rapidly, the slag gets trapped inside the weld. This weakens the weld strength and is not desirable. When the required weld thickness is large, it is made by several passes. In such cases, the slag should be removed after the completion of each pass. If this is not done properly, it also results in the inclusion of slag. 5. Cracks Cracks are the most serious weld defects since it reduces the weld strength directly. This results mostly due the relative differences in internal stresses in the weld. The direction of the weld can be either along the longitudinal or transverse direction of weld. They can be seen on the surface or present inside the weld. They can be avoided by using good quality electrodes, adopting uniform rate of welding and ensuring slower cooling periods. 6. Lamellar tearing This is the formation of cracks beneath the weld. The high temperature during welding causes large relative strains in the base metal due to localised stresses and results in tearing of the base metal. This can be prevented by choosing proper welding techniques and adopting uniform rate of welding.
10.0 WELD DISTORTIONS During welding operation, proper care must be ensured to avoid weld distortions. Improper welding techniques results in weld distortions. Some of
the commonly observed distortions during welding are Transverse shrinkage, Longitudinal shrinkage, Angular change, Rotational distortion, Longitudinal bending distortion and Bucking distortion. These distortions are shown in Fig. 26.
a) Transverse shrinkage
b) Longitudinal shrinkage
c) Angular change
d) Rotational distortion
f) Buckling distortion
11.0 IMPORTANT CODAL PROVISIO NS OF IS 800 : 2007 WITH RESPECT TO WELDING The welds and welding shall conform to the following codes:
IS 816 : 1969 Code of practice for the use of metal arc welding for general construction in mild steel IS 9595 : 1996 Metal arc welding of carbon and carbon manganese steels Cl. 10.5.1.1 End Return s
>2a
Fig. 27 Details of end returns of weld
Fillet welds terminating at the ends or sides of parts should be returned continuously around the corners for distance of not less than twice the size of the weld, unless it is impractical. This is particularly important on the tension end of parts carrying bending loads. Cl. 10.5.1.2 Lap Joint
In lap joints the minimum lap should be not less than four times the thickness of the thinner part joined. Single end fillet should be used only when lapped parts are restrained from openings. When end of an element is connected only
by parallel longitudinal fillet welds, the length of the weld along either edge should be not less than the transverse spacing between longitudinal welds.
Cl. 10.5.2 Size of weld 10.5.2.1 The size of normal fillets shall be taken as the minimum weld leg size. For deep penetration welds, where the depth of penetration beyond the root run is 2.4 mm (minimum), the size of the fillet should be taken as the minimum leg size plus 2.4 mm.
10.5.2.2 For fillet welds made by semi-automatic or automatic processes, where the depth of penetration is considerably in excess of 2.4 mm, the size shall be taken considering actual depth of penetration subject to agreement between the purchaser and the contractor.
10.5.2.3 The size of fillet welds shall not be less than 3 mm. The minimum size of the first run or of a single run fillet weld shall be as given in Table 5, to avoid the risk of cracking in the absence of preheating.
Table 5 Minimum weld size Thickness of Thicker Part Over, mm -10 Upto and including, mm 10 20 Minimum Size mm 3 5
20 32
32 50
10.5.2.4 The size of butt weld shall be specified by the effective throat thickness.
The effective throat thickness te (Fig. 31) of a fillet weld shall not be less than 3 mm and shall generally not exceed 0.7t, and 1.0t under special circumstances, where t is the thickness of the thinner plate of elements being welded.
10.5.3.2 For the purpose of stress calculation in fillet welds joining faces inclined to each other, the effective throat thickness shall be taken as K times the fillet size, where K is a constant, depending upon the angle between fusion faces, as given in Table 6.
60 90
0 0 0 0
0 0 0 0 0
91 100
10.5.3.3 The effective throat thickness te (Fig. 32) of a complete penetration butt weld shall be taken as the thickness of the thinner part joined, and that of an incomplete penetration butt weld te (Fig. 32) shall be taken as the minimum thickness of the weld metal common to the parts joined, excluding reinforcement.
Cl. 10.5.4 Effective Length 10.5.4.1 The effective length of fillet weld shall be taken as only that length which is of the specified size and required throat thickness. In practice the actual length of weld is made of the effective length shown in drawing plus two
times the weld size, but it should not be less than four times the size of the weld.
10.5.4.2 The effective length of butt weld shall be taken as the length of the continuous full size weld, but it should not be less than four times the size of the weld.
Cl. 10.5.5 Intermittent Welds 10.5.5.1 The intermittent fillet welding shall have an effective length of not less than four times the weld size, with a minimum of 40 mm, except as otherwise specified.
10.5.5.2 The clear spacing between the effective lengths of intermittent fillet weld shall not exceed 12 and 16 times the thickness of thinner plate joined, for compression and tension joint respectively, and in no case be more than 200 mm.
10.5.5.3 The intermittent butt weld shall have an effective length of not less than four times the weld size and the longitudinal space between the effective length of welds shall not more than 16 times the thickness of the thinner part joined, except as otherwise specified. The intermittent welds shall not be used in positions subject to dynamic, repetitive and alternate stresses.
10.5.7.1 Shop welds 10.5.7.1.1 Fillet welds The design strength of a fillet weld, fwd, shall be based on its throat area.
fwd = fwn / mw in which fwn = fu / 3
where fu = smaller of the ultimate stress of the weld and the parent metal mw = 1.25 = partial safety factor
10.5.7.1.2 Butt welds Butt welds shall be treated as parent metal with a thickness equal to the throat thickness, and the stresses shall not exceed those permitted in the parent metal.
10.5.7.2 Site Welds The design strength in shear and tension for site welds made during erection of structural members shall be calculated as per 10.5.7.1 but using a partial safety factor mw of 1.5.
10.5.8.1 Where a fillet weld is applied to the square edge of a part, the specified size of the weld should generally be at least 1.5 mm less than the edge thickness in order to avoid washing down of the exposed arris (Fig. 33).
1.5 mm a
10.5.8.2 Where the fillet weld is applied to the rounded toe of a rolled section, the specified size of the weld should generally not exceed 3/4 of the thickness of the section at the toe (Fig. 34).
1/4 t t
10.5.8.3 Where the size specified for a fillet weld is such that the parent metal will not project beyond the weld, no melting of the outer cover or covers shall be allowed to occur to such an extent as to reduce the throat thickness (Fig. 35)
Fig. 35 Full size fillet weld applied to the edge of a plate or section
10.5.8.4
members subject to dynamic loading, the fillet weld shall be of full size, that is, with its leg length equal to the thickness of the plate or section, with the limitations enumerated in 10.5.8.3.
10.5.8.5
size with a throat thickness not less than 0.5t where t is the thickness of the part as shown in Fig. 36. The difference in thickness of the welds shall be negotiated at a uniform slope.
Cl. 10.5.9 Stresses Due to Individual for ces When subjected to either compressive or tensile or shear force alone, the stress in the weld is given by:
fa or q = where fa = calculated normal stress due to axial force in N/mm2 q = shear stress in N/mm
2
P tt l w
P = force transmitted (axial force N or the shear force Q) tt = effective throat thickness of weld in mm lw= effective length of weld in mm
Cl. 10.5.10 Combination of stresses 10.5.10.1 Fillet Welds 10.5.10.1.1 When subjected to a combination of normal and shear stress, the equivalent stress fe shall satisfy the following
f e = fa + 3 q 2<
where
fu 3 mw
fa = normal stresses, compression or tension, due to axial force or bending moment (10.5.9), and q = shear stress due to shear force or tension (10.5.9)
10.5.10.2.2 Combined bearing, bending and shear - Where bearing stress, fbr is combined with bending (tensile or compressive) and shear stresses under the
most unfavorable conditions of loading, the equivalent stress fe is obtained from the following formulae:
fe =
where
f b + f br + f b f br + 3q 2
fe = equivalent stress fb = calculated stress due to bending in N/mm q = shear stress in N/mm
2 2
Cl. 10.8 Intersection s Members or components meeting at a joint shall be arranged to transfer the design actions between the parts, wherever practicable, with their centroidal axes meeting at a point. Where there is eccentricity at joints, the members and components shall be designed for the design bending moments, which result due to eccentricity. The disposition of fillet welds to balance the design actions about the centroidal axis or axes for end connections of single angle, double angle and similar type members is not required for statically loaded members but is required for members, connection components subject to fatigue loading. Eccentricity between the centroidal axes of angle members and the gauge lines for their bolted end connections may be neglected in statically loaded members, but shall be considered in members and connection components subject to fatigue loading.
Cl. 10.11 Analysis of a Bolt/Weld Group 10.11.1 Bolt/Weld Group Subject to In-plane Loading
10.11.1.1 General Method of Analysis The design force in a bolt/weld in a bolt/weld group or design force per unit length in a bolt/weld group subject to in-plane loading shall be determined in accordance with the following: a) The connection plates shall be considered to be rigid and to rotate relative to each other about a point known as the instantaneous centre of rotation of the group. b) In the case of a group subject to a pure couple only (Fig. 37a), the instantaneous centre of rotation coincides with the group centroid. In the case of in-plane shear force applied at the group centroid (Fig. 37b), the instantaneous centre of the rotation is at infinity and the design force is uniformly distributed throughout the group. In all other cases (Fig. 37c), either the results of independent analyses for a pure couple alone and for an in-plane shear force applied at the group centroid shall be superposed, or a recognized method of analysis shall be used. c) The design force in a bolt or design force per unit length at any point in the group shall be assumed to act at right angles to the radius from that point to the instantaneous centre, and shall be taken as proportional to that radius.
Fig. 37 Location of Pure couple and In-plane shear with respect to centroid
10.11.2 Bolt/Weld group Subject to Out-of-Plane Loading 10.11.2.1 General Method of Analysis The design force of a bolt in bolt group or design force per unit length in the fillet weld group subject to out-of-plane loading (Fig. 38) shall be determined in accordance with the following: a) The design force in the bolts per unit length in the fillet weld group resulting from any shear force or axial force shall be considered to be equally shared by all bolts in the group or uniformly distributed over the length of the fillet weld group. b) The design force resulting from a design bending moment be considered to vary linearly with the centroidal axes. distance from the shall
relevant
i) In bearing type of bolt group plates in the compression side of the neutral axis and only bolts in the tension side of the neutral axis may be considered for calculating the neutral axis and second moment of area. ii) In the friction grip bolt group only the bolts shall be considered in the calculation of neutral axis and second moment of area. iii) The fillet weld group shall be considered in isolation from the connected element; for the calculation of centroid and second moment of the weld length.
Bracket
10.11.2.2 Alternative Analysis The design force per unit length in a fillet weld/bolt group may alternatively be determined by considering the fillet weld group as an extension of the connected member and distributing the design forces among the welds of the fillet weld group so as to satisfy equilibrium between the fillet weld group and the elements of the connected member.
Single V is an incomplete penetration welding. Hence the throat thickness is 5/8 of the thickness of thinner plate. te = 5/8 t = (5/8) x 8 = 5 mm Effective length of weld Lw = width of plate = 200 mm. Strength of weld, P = L x tt x fy / mw Cl. 6.2
th
Case (ii) : Double V groove weld (Fig. 40) In this case, complete penetration results due to Double V groove.
Effective throat thickness is 8mm which is the thickness of the thinner plate. te = 8 mm Strength of weld, P = L x tt x fy / mw Cl. 6.2
2. Find the size and length of the fillet weld for the lap joint to transmit a factored load of 120 kN as shown in Fig. 41. Assume site welds, Fe 410 grade steel and E41 electrode. Assume width of plate as 75 mm and thickness as 8 mm.
Solution Minimum size of weld for 8 mm thick section = 3 mm (Table 5, Cl. 10.5.2.3) Maximum size of weld = 8 1.5 = 6.5 mm (Cl. 10.5.8.1) Choose the size of weld, a = 6 mm Effective throat thickness = te = 0.70 a = 4.2 mm Strength of 6 mm weld / mm length = 4.2 x 410 / (3 x 1.5) Cl. 10.5.7.1.1 = 662.7 N/mm Assuming only two longitudinal welds along the sides Required length of weld = 120 x 10 / 662.7 = 181 mm Length to be provided on each side = 181/2 = 90.5 mm > 75 mm (width of plate) Hence, provide 90.5 mm weld on each side with an end return of 2x 6 = 12 mm Overall length of the weld provided = 2 x (90.5 + 2 x 6) = 205 mm
3
3. Two plates are connected to form a fillet joint using 6mm weld. Welding is provided on three sides with a lap of 300mm as shown in Fig.42. Find the strength of the joint. If welding is provided on all four sides (Fig. 44), determine the strength of the joint. Also find the percentage increase in the strength. Use Fe 410 steel with yield stress 250 MPa. Assume shop welding.
Solutio n Case (i) : Welding on three sides (Fig. 42) Lw = 300 + 200 + 300 = 800 mm Design strength of fillet weld joint, P1 = 0.7a fwd Lw / mw Cl. 10.5.7.1.1 = 0.7 x 6 x (410 /3) x 800 / 1.25 = 6,36,286 N Hence, allowable load = 6,36,286 / 1.5 = 4,24,191 N Case (ii) : Welding on four sides (Fig. 43)
Lw = 300 + 200 + 300 + 200 = 1000 mm Design strength of fillet weld joint, P2 = 0.7a fwd Lw / mw Cl. 10.5.7.1.1 = 0.7 x 6 x (410 /3) x 1000 / 1.25 = 7,95,358 N Hence, allowable load = 7,95,358 / 1.5 = 5,30,239 N
4. Determine the size of the weld required for the bracket connection shown in Fig. 44. Assume shop welding. Solution Eccentricity, e = 100 + 75 = 175 mm
Torsional moment , M = 60 x 175 = 10,500 kNmm Considering unit thickness of weld at root Ip = Izz + Iyy = 3.08 x 10 mm
6 4
Further, rmax = 125 mm Shear stress due to torsional moment, f2 = M x rmax / Ip = 426 MPa Resultant stress in the critical part of the weld / mm width R = (f1 + f2 + 2 f1 f2 cos ) 0.5 = 530 MPa Strength of the weld per unit length and thickness, P P = 0.7a fwd Lw / mw = 0.7 a (410/3) 1 / 1.25 = 132.6 a N Equating the resultant, R with the strength of weld, P (i.e., R = P) a = 3.99 mm Size of weld to be provided = 4mm
2 2
5. Determine the load, V that can be applied on the bracket shown in Fig. 45. Use 6 mm field fillet welding. Solution Shear stress due to direct force, q = V / (2 x 200 x 1) = 0.0025 V 2 N/mm Moment on weld, M = 200 V N-mm Considering unit thickness of weld at root, Moment of inertia Iz = 2 (1x 200 ) / 12 = 1.33 x 10 mm
3 6 4
Normal stress due to bending in tension, fa = M y / Iz Here, M = 200 V N-mm, y = 100 mm, Iz = 1.33 x 10 mm
6 4
Hence,
fa = 0.015 V
Equivalent stress, fe is computed as (cl. 10.5.10.1.1) fe = ( fa + 3 q ) 0.5 = 0.0156 V For 6 mm fillet weld (field weld) Strength of weld/mm , fwd =0.7 x 6 (410 / 3) / 1.50 = 662.8 N/mm Equating the equivalent stress, fe with the strength of 6 mm weld, fwd fe = fwd 0.0156 V = 662.8 Hence, V = 42487 N = 42.5 kN For the current bracket
2 2
13.0 References
1. Subramanian, N., Design of steel structures, Oxford university press, New Delhi, 2009. 2. Bhavikatti, S.S., Design of steel structures, I.K.I. Publishing house, New Delhi, 2010. 3. IS 800 2007, Code of practice for General construction in steel, Bureau of Indian Standards, New Delhi, 2007.