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The calculation is intended for the geometrical design and strength control of statically loaded
welded connections of machine structures manufactured from carbon steels. The program
enables you to design over 50 of the most common types of welded connections stressed by
various combinations of load. The calculation deals with the following tasks:
1. Design of connections with butt welds.
2. Design of connections with fillet welds.
Theory - Fundamentals.
The welded connections are solid, non-detachable connections based on the principle of local
melting of connected parts using heat or pressure. The joining of components proper may be
achieved technically using two methods:
Fusion welding (arc, flame, plasma, laser, thermite, electroslag, ... welding)
The weld is a result of local melting of the material of connected parts, and usually also filler
metal, without pressure.
An optimum result of the welding process should be a weld with mechanical properties similar as
far as possible to the properties of the basic material. According to their function, we can divide
welds into:
Force welds - load-bearing welds used to transfer external load
Tack welds - welds providing only compactness of the whole (with no or negligible
external load)
Caulk welds - welds providing staunchness of connected parts (vessels, pipelines, etc.)
This program is designed for the calculation of statically loaded welded connections of machinery
structures manufactured from carbon steels, for working temperatures ranging from -20 to
150C. The program enables you to perform geometrical design and strength checks of force
connections with the most common types of fusion welds and connections with spot resistance
welds. The calculation does not consider the sudden formation of fragile fractures, change in
material properties due to temperature, impact of own tensions or concentration of stress in the
weld.
An accurate theoretical solution to force and strength conditions is an extremely complicated
problem for welded connections, even for welds with simple shapes. That is why common
technical calculations are based on a range of conventions and simplified premises. In view of the
strength checks, welded parts are usually considered a single compact part with a dangerous
spot (section) in the welded area. On the grounds that there is an even distribution of stress in
the active weld section, only theoretical rated stress in the specified section is specified for the
respective load, regardless of the technological workmanship of the weld or potential internal
tension. For connections with multiple welds, an even load on individual welds is assumed.
The strength checks of the connection are performed by simple comparison of the calculated
rated stress with the permissible stress in the weld. Permissible weld stress "SwA" is usually
specified from the value of the yield strength of the basic material "Re" based on the required
safety.
When selecting the safety coefficient "FS", it is necessary to consider the specific factors of
welded connections in addition to the general principles used to specify the safety coefficients.
The required safety degree should respect all the facts that were not considered in the calculation
of rated stresses (technological workmanship of weld, weld quality, internal tension, weld
homogeneity, shape and finish of weld surface, weld reinforcement, ignites and penetrations,
etc.). Last but not least, the direction of stress and the anisotropic properties of material in the
weld must also be considered. Different weld material properties in the vertical and horizontal
direction result in differing values of the safety coefficient depending on the type, workmanship
and load type of the welded connection.
From the above mentioned, it is obvious that the most complicated task in strength checks of the
welded connection applies to the proper choice of safety coefficient. General procedures for
setting safety coefficients can be found in the document "Coefficients of safety", while specific
recommendations regarding welded connections are given at the end of the chapter. The
procedures to specify the rated stress for individual types of welds are detailed in the following
paragraphs.
Butt welds.
Butt welds originate in the joint gap of connected parts and are usually used as load-bearing,
force welds. In order to achieve perfect workmanship of the welds, it is usually necessary to
perform modification of the contact surfaces of the connected parts. The method of welded
surface treatment is set by the workmanship of the connection, the thickness of the welded
parts, the welding method and the accessibility of the welded spot.
When designing and performing the strength checks of welded connections, the weldment with a
butt weld is considered as a solid component with a dangerous spot in the area of the weld. The
load-bearing weld section will be the basic characteristic of the connection for the assessment of
its load-bearing capacity.
In the calculation of butt welds, the type of welds (method of weld surface treatment) or potential
weld root reweldment are not considered. The load-bearing section of the butt weld is then
specified only by its thickness "a" and length "L".
Note: This program is designed for the calculation of connections with uniform, fully penetrated
butt welds. The recommended procedures for handling special cases of connections (partly
welded welds, intermittent welds, combined welds) can be found at the end of this chapter.
Weld throat thickness:
In order to specify the load-bearing section, the thickness of the thinner of the welded parts is
considered as the butt weld throat thickness "a". Reinforcement of the weld surface and root is
not considered.
Hint: This program is provided with the function of automatic effective weld length calculation -
see the switch on line [2.6].
Strength solution of welds:
When performing strength checks of butt welds, the rated stress in the load-bearing weld section
must be specified first. Depending on the respective load, the individual stress components are
specified in the direction normal to the weld and in the direction parallel to the weld (ll). The
calculated rated stresses must not exceed the values for the permissible stress.
When specifying permissible stresses, the anisotropic properties of the material in the area of the
weld must be considered. Different properties of the material result in differing values of
permissible stress of the weld in the normal and parallel direction.
For connections stressed by combined load, the resulting "equivalent" stress in the weld is
specified from the relation:
The following table specifies the relations used in the calculation of rated stresses (for respective
load and workmanship of the connection):
Load Rated stress [MPa, psi]
Tensile/
Press.
Shear
Bend
Bend
Twist
Tensile
Tensile/
Press.
Shear
Bend
Tensile/
Press.
Shear
Bend
Twist
where:
a .... weld throat thickness [mm, in]
Aw ... weld throat area [mm2, in2]
D .... tube diameter [mm, in]
.... weld angle []
F .... acting force [N, lb]
Fn ... normal force [N, lb]
Fs ... shear force [N, lb]
L .... effective weld length [mm, in]
M .... bending moment [N mm, lb in]
... normal stress vertical to the weld direction [MPa, psi]
ll ... normal stress parallel to the weld direction [MPa, psi]
T .... torque [N mm, lb in]
... shear stress vertical to the weld direction [MPa, psi]
ll ... shear stress parallel to the weld direction [MPa, psi]
Zw ... module of weld section [mm3, in3]
Connections with partly welded welds:
Connections with partly welded butt welds are usually handled as fillet welds, with the weld
throat (effective) thickness "a".
The other, less appropriate solution method applies to the use of the normal calculation of butt
welds with the weld throat thickness "2a" and adequately increased safety degree.
Connections with combined welds:
Connections with a combined butt and fillet weld are usually handled as butt welds with the weld
throat (efficient) thickness "a".
Weld throat thickness:
where for:
Note: This program is designed for the calculation of welds with uniform fillet welds. The
recommended methods of handling connections with intermittent welds or with combined welds
can be found at the end of this chapter.
Weld throat thickness:
The fillet weld throat thickness "a" is defined as the height of the biggest isosceles triangle
inscribed into a weld section without penetration.
Recommendation: The fillet weld thickness is chosen depending on the used material and
thickness of the welded parts. As the information regarding the recommended weld thickness
given in the literature differs significantly, follow the company procedures in choosing the weld
thickness. In order to specify the approximate minimum thickness of the fillet weld, the following
informative relation can be used for the steel strength Rm370..420 MPa:
with tmin for thickness of the thinner of the connected materials. For steels with higher strength
(Rm520 MPa), the weld thickness should be approx. 1 to 2 mm higher.
Effective weld length:
In a normal type of weld, so-called "end down-slopes" are formed. They result in weakening of the
section at the weld's beginning and end. The effective weld length will then be smaller than the
actual length (reduced by a worse-quality weld beginning and end). For more accurate
calculations, we therefore recommend controlling the load-bearing capacity of welds only for that
part (length) of the weld that has a rated section. A common method of specifying the effective
length "L" depending on the weld workmanship is shown schematically in the picture.
Hint: This program is provided with a function of automatic effective weld length calculation -
see the switch on line [3.12] or [4.12].
Recommendation: The length of the fillet weld should range between 5a< L< 70a. For longer
welds, it is more practical to use an intermittent weld. For very long welds (150a<L<400a)
stressed in the weld direction, it is necessary, for the sake of calculation, to perform correction of
the effective weld length using the coefficient:
When specifying permissible stresses, the anisotropic properties of the material in the area of the
weld must be considered. Different properties of the material result in differing values of
permissible stress of the weld in the normal and parallel direction.
A common method of handling welds with fillet welds is further presented in a typical example of
connecting a beam using a double-sided fillet weld.
Depending on the acting load, we can use the following relations to specify the individual
components of stress at point "A" of the weld:
- load with normal force Fz:
where:
Aw ... weld throat area [mm2, in2]
Iw ... moment of inertia of the weld [mm4, in4]
Jw ... polar moment of inertia of the weld [mm4, in4]
... normal stress vertical to the weld direction [MPa, psi]
ll ... normal stress parallel to the weld direction [MPa, psi]
... shear stress vertical to the weld direction [MPa, psi]
ll ... shear stress parallel to the weld direction [MPa, psi]
For connections stressed by combined load, the resulting "equivalent" stress in the weld is
specified from the relation:
The sectional properties for the selected basic shapes of weld groups can be found in the
following table. In order to specify the polar moment of inertia of the weld, you can use the
following relation:
S
ha Aw [mm2, in2] IwX [mm4, in4] IwY [mm4, in4]
pe
Centre of gravity of weld group:
where:
a .... weld throat thickness [mm, in]
B .... width of weld group [mm, in]
D .... weld diameter [mm, in]
H .... height of weld group [mm, in]
L .... weld length [mm, in]
s .... flange thickness [mm, in]
t .... web thickness [mm, in]
Connections with combined welds:
Connections with a combined butt and fillet weld are usually handled as butt welds with the weld
throat (efficient) thickness "a".
Weld throat thickness:
where for:
These welds are not suitable for the joining of thicker plates and are usually used for thinner
plates up to approx. 15 mm thick. In view of the stress, slot welds are more preferable due to the
better quality of penetration of the weld root. A better quality of the weld, i.e. better strength
characteristic of the joint, can be achieved by sloped walls of openings.
Recommended weld dimensions:
Hole diameter ... d 2s
Slot width ... d 2s
Slot length ... L 2d
Strength solution of welds:
Two types of damage appear in plug and slot welds:
1) shear in the weld base surface
2) tear in the weld circumferential surface
During strength checks, both possible types of damage must be assessed. We can specify the
resulting rated stress from the relation:
The sizes of calculated weld surfaces Aw are specified for both weld types in the table:
Base area
of weld
[mm2, in2]
Circumfer
ential
area
[mm2, in2]
where:
F .... acting force [N, lb]
d .... plug weld diameter, or slot weld width [mm, in]
i ..... number of welds
L .... slot weld length [mm, in]
s .... plate thickness [mm, in]
Spot (resistance) welds.
Spot resistance welds are usually used to connect thin plates and thin-walled parts. They are
especially very useful in lot production. The connections with spot welds are not very appropriate
for transferring high forces. In view of the type of stress, we distinguish two basic types of
connections with spot welds:
- connections with welds stressed in shear (lap joints)
- connections with welds stressed in tear (by tension)
In technical practice, not more than 3 parts with maximum total thickness up to approx. 15 mm
are allowed to be joined for connections with resistance welds. The thickness ratio for individual
parts should not exceed 1:3. The welds should be positioned towards the external force so that
they are always only stressed in shear. Spot welds stressed in tension have significantly lower
load-bearing capacity, which is why their use is not recommended. Lap welds can be made as
single-shear or double-shear. A minimum of 2 and maximum of 5 spot connections should be
located in the direction of acting force.
where:
Awa ... area of the spot weld section [mm2, in2]
Awc ... cylindrical area of the weld [mm2, in2]
F .... acting force [N, lb]
d .... spot weld diameter [mm, in]
i ..... number of welds
s .... plate thickness [mm, in]
Safety of welded connections, used calculation methods.
An accurate theoretical solution to force and strength conditions is an extremely complicated
problem for welded connections, even for welds with simple shapes. That is why common
technical calculations are based on a range of conventions and simplified premises. That logically
results in certain disagreement between the solution models commonly used in practice. That is
why the program is provided with an option to select from three different calculation methods.
Although all three specified methods use almost a similar way of theoretical handling of tension
in the examined spot of the weld, they differ in the method of evaluating the total load-bearing
capacity of the designed connection. That is why each calculation method operates with its own
safety rate differing in quality. The choice of an appropriate method will then depend on the
user's specific requirements and experience.
The following paragraphs provide a detailed description of individual calculation methods.
1. Basic calculation method.
This method represents a general method of handling welded connections and is based on the
most frequent calculation methods for welded connections of machinery equipment mentioned in
the literature.
Depending on the respective type, workmanship and load of the welded connection, this method
calculates the respective theoretical rated stress in the load-bearing weld section (normal, shear,
or equivalent) in the first step. The strength checks of the weld are then performed by simple
comparison of the calculated stress to the yield strength of the basic material. With respect to the
type of calculated stress, we can describe the conditions of the load-bearing capacity of the weld
using the following relations:
The required safety of the weld stress is then the ratio between the value of the yield strength of
the basic material and the value of the maximum admissible stress of the specific weld.
This method is disadvantageous due to the rather complicated procedure in specifying the
suitable safety rate minimum value. In addition to the common (qualitative) criteria, specific
factors of the specific welded connection (type, workmanship and the way of connection load)
must be considered when choosing the required safety. The required safety for the yield strength
"FSy" is then defined as the product of two safety coefficients FSy = FS1 * FS2.
Safety coefficient FS1:
Depends on the direction of the acting stress and the anisotropic properties of the material in the
examined weld spot. Its value should also consider the technological weld parameters. With
respect to the type, workmanship and the way of connection load, it is chosen from the range 1
to 2.
Safety coefficient FS2:
It considers qualitative parameters. With respect to the accuracy and value of input information,
connection importance, production quality, operating conditions and calculation accuracy, it is
usually chosen from 1.1 to 2.
Hint 1: You can find the informative values for the choice of safety coefficients FS1 and FS2 in
chapter [1.3] of the Help.
Hint 2: This method is suitable for experienced users who are able to perform a sound design of
the required safety degree depending on the specific type, workmanship and load of the welded
joint.
The strength checks of the weld are then performed by comparison of the calculated comparative
stress to the yield strength of the basic material. Regardless of the type, workmanship or the way
of load of the welded joint, we can describe the condition of load-bearing capacity using a single
relation:
The required safety against the yields point "FSy" will consider only the qualitative parameters of
the welded connection for this method. With respect to the accuracy and value of input
information, connection importance, production quality, operating conditions and calculation
accuracy, it is usually chosen from 1.1 to 2.
Hint 1: You can find the informative values for the choice of safety coefficient FSy in chapter
[1.5] of the Help. The values of the predefined conversion coefficient may be adjusted in
paragraph [3.1] on the sheet "Options".
Hint 2: This method is especially suitable for less experienced users. Its use may be
advantageous in case of a comparative calculation when several designed solutions with a
different type of weld need to be compared.
As the required safety level is usually already included in the value of the prescribed permissible
stress, the applied safety degree "FS" is used as an auxiliary quantity and only describes a
certain degree of "over-dimensioning" of the designed connection. The safety value "FS" will then
depend on the procedure applied by the user in order to define the permissible stress, and it is
usually FS1.
Hint 1: Some values of permissible stresses that are specified in professional literature are
derived for a different methodology of comparative stresses calculation. That is why this method
enables variable behaviour of the calculation. Set the basic parameters for the calculation of
comparative stresses in paragraph [3.10] on the sheet "Options".
Hint 2: Use this method if you need to check the load-bearing capacity of the welded connection
for known (rated) permissible connection stress.
Process of calculation.
A typical calculation / connection design includes the following steps:
1. Set the required calculation units (SI / Imperial). [1.1]
2. Choose the proper calculation method and set the required safety level [1.2].
5. On the first line of the chapter [X.1] select the required workmanship (shape) of the
connection.
7. Check the respective check boxes in the paragraph "Loading of the connection" to
select the appropriate load combination. Specify the size of the selected loads.
8. Check the calculated safety of the designed connection in the paragraph "Strength
checks of the connection".
9. Save the workbook with the satisfactory solution with a new name.
Fillet welds
1.2 ...
- end welds
1.5
1.3 ...
- side welds
1.6
* higher values - flat welds, unfinished welds, welds without
penetration, thicker welds, manual welding
* lower values - concave welds, penetrated welds, lower-
thickness welds, automatic welding in CO2 or under welding flux
Butt welds originate in the joint gap of connected parts and are usually used as load-bearing,
force welds. In order to achieve perfect workmanship of the welds, it is usually necessary to
perform modification of the contact surfaces of the connected parts. The method of welded
surface treatment is set by the workmanship of the connection, the thickness of the welded
parts, the welding method and the accessibility of the welded spot.
Warning: This program is designed for the calculation of connections with uniform, fully
penetrated butt welds. The recommended procedures for handling special cases of connections
(partly penetrated welds, intermittent welds, combined welds) can be found in the theoretical
part of the Help.
Designing procedure for the connection:
1. On line [2.1] choose the required connection type.
3. On line [2.6] select whether the connection is to be controlled only for the effective weld
length.
4. Check the appropriate check boxes in paragraph [2.7] to set the respective load
combination. Specify the values of selected loads.
5. If "Method of permissible stresses" (see. [1.7]) is used, set the permissible stress
value on line [2.15].
7. If you want to optimize the connection dimensions or the designed connection does not
comply with the strength checks, use the "min" buttons in paragraph [2.2] to find the
suitable connection dimensions.
8. If you want to establish the maximum admissible load for the respective connection, use
the "max" button in paragraph [2.7].
Hint: Detailed information on the butt weld calculation can be found in the theoretical part of the
Help.
2.1 Connection type.
Check the switch with the respective image to select the required connection type.
2.2 Dimensions of the connection.
Use this paragraph to set all required connection dimensions.
Hint: After any of the "min" buttons located to the right of the input fields are pressed, the
program will find the minimum suitable value of the respective dimension for the respective load,
selected material and required connection safety.
2.6 Effective weld length.
In a normal type of weld, so-called "end down-slopes" are formed. They result in weakening of the
section at the weld's beginning and end. The effective weld length will then be smaller than the
actual length (reduced by a worse-quality weld beginning and end). For more accurate
calculations, we therefore recommend controlling the load-bearing capacity of welds only for that
part (length) of the weld that has a rated section.
Check this switch in order to consider only the effective weld length during the strength checks of
the connection. The program will set the effective length automatically from the specified
dimensions. If the check box is unchecked, the load-bearing capacity of the weld will be
calculated directly for the dimensions of the connection set in paragraph [2.2].
Recommendation: The calculations using the effective length for the weld control err to the
side of safety. Therefore, the switch should preferably be on constantly. Exceptions include cases
when the weld is provided with special treatment (see the figure) or if it is impossible to use the
automatic calculation for the effective length setting (e.g. for intermittent welds).
Warning: This program is designed for the calculation of welds with uniform fillet welds. The
recommended methods of handling connections with intermittent welds or with combined welds
can be found in the theoretical part of the Help.
Designing procedure for the connection:
1. 1. On line [3.1] choose the required connection type (form of weld group).
3. In paragraph [3.11] set the respective parameters for the connection and calculation.
4. Check the appropriate check boxes in paragraph [3.15] to set the respective load
combination. Specify the values of selected loads.
5. If "Method of permissible stresses" (see. [1.7]) is used, set the permissible stress
value on line [3.26].
7. If you want to optimize the connection dimensions or the designed connection does not
comply with the strength checks, use the "min" buttons in paragraph [3.2] to find the
suitable connection dimensions.
8. If you want to establish the maximum admissible load for the respective connection, use
the "max" button in paragraph [3.15].
Hint: Detailed information on the fillet weld calculation can be found in the theoretical part of the
Help.
3.1 Form of weld group.
Use a switch with the respective picture to choose the required type of connection (form of weld
group).
Note: The switches marked with a blue weld in the picture (connections no. 17, 18 and 36) are
used for the calculation of connections without closer details regarding the form of weld group.
For a connection with a form of weld group that is not axial symmetric (connection no. 18) we
recommend performing the check of stress in the respective weld area (the most distant from the
centre of gravity) gradually in all four quadrants.
3.2 Dimensions of the connection.
Use this paragraph to set all required connection dimensions.
Hint 1: You can find the recommended procedures to choose the appropriate weld dimensions in
the theoretical part of the Help.
Hint 2: After any of the "min" buttons located to the right of the input fields are pressed, the
program will find the minimum suitable value of the respective dimension for the respective load,
selected material and required connection safety.
3.3 Weld throat thickness.
The fillet weld throat thickness is defined as the height of the biggest isosceles triangle inscribed
into a weld section without penetration.
Hint: The minimum fillet weld thickness is usually chosen depending on the used material and
the thickness of the welded parts. You can find the recommended procedures to choose the
appropriate weld thickness in the theoretical part of the Help.
3.8 Standard profiles.
This paragraph is used to enable the setting (automatic completion) of the respective dimensions
of the connection [3.2] for connections with welded on beams with standardized profiles.
When choosing the profile, proceed as follows:
1. Choose the required profile type (standard) from the drop-down menu [3.9].
3. Press the "<" button in the left part of the list to transfer the dimensions of the selected
profile to the input fields of paragraph [3.2].
Note: This paragraph is only functional for the selected forms of weld groups matching the
standardized profiles.
3.12 Effective weld length.
In a normal type of weld, so-called "end down-slopes" are formed. They result in weakening of the
section at the weld's beginning and end. The effective weld length will then be smaller than the
actual length (reduced by a worse-quality weld beginning and end). For more accurate
calculations, we therefore recommend controlling the load-bearing capacity of welds only for that
part (length) of the weld that has a rated section.
Check this switch in order to consider only the effective weld length during the strength checks of
the connection. The program will set the effective length automatically from the specified
dimensions. If the check box is unchecked, the load-bearing capacity of the weld will be
calculated directly for the dimensions of the connection set in paragraph [3.2].
Recommendation: The calculations using the effective length for the weld control err to the
side of safety. Therefore, the switch should preferably be on constantly. Exceptions include cases
when the weld is provided with special treatment (see the figure) or if it is impossible to use the
automatic calculation for the effective length setting (e.g. for intermittent welds).
Double-shear connection:
Warning: This program is designed for the calculation of welds with uniform fillet welds. The
recommended methods of handling connections with intermittent welds or with combined welds
can be found in the theoretical part of the Help.
Designing procedure for the connection:
1. 1. On line [4.1] choose the required connection type (form of weld group).
3. In paragraph [4.11] set the respective parameters for the connection and calculation.
4. Check the appropriate check boxes in paragraph [4.14] to set the respective load
combination. Specify the values of selected loads.
5. If "Method of permissible stresses" (see. [1.7]) is used, set the permissible stress
value on line [4.26].
7. If you want to optimize the connection dimensions or the designed connection does not
comply with the strength checks, use the "min" buttons in paragraph [4.2] to find the
suitable connection dimensions.
8. If you want to establish the maximum admissible load for the respective connection, use
the "max" button in paragraph [4.14].
Hint: Detailed information on the fillet weld calculation can be found in the theoretical part of the
Help.
4.1 Form of weld group.
Use a switch with the respective picture to choose the required type of connection (form of weld
group).
Note: The switches marked with a blue weld in the picture (connections no. 25 and 26) are used
for the calculation of connections without closer details regarding the form of weld group.
4.2 Dimensions of the connection.
Use this paragraph to set all required connection dimensions.
Hint 1: You can find the recommended procedures to choose the appropriate weld dimensions in
the theoretical part of the Help.
Hint 2: After any of the "min" buttons located to the right of the input fields are pressed, the
program will find the minimum suitable value of the respective dimension for the respective load,
selected material and required connection safety.
4.3 Weld throat thickness.
The fillet weld throat thickness is defined as the height of the biggest isosceles triangle inscribed
into a weld section without penetration.
Hint: The minimum fillet weld thickness is usually chosen depending on the used material and
the thickness of the welded parts. You can find the recommended procedures to choose the
appropriate weld thickness in the theoretical part of the Help.
4.8 Standard profiles.
This paragraph is used to enable the setting (automatic completion) of the respective dimensions
of the connection [4.2] for connections with welded on beams with standardized profiles.
When choosing the profile, proceed as follows:
1. Choose the required profile type (standard) from the drop-down menu [4.9].
2. Choose the respective profile dimension from list [4.10].
3. Press the "<" button in the left part of the list to transfer the dimensions of the selected
profile to the input fields of paragraph [4.2].
Note: This paragraph is only functional for the selected forms of weld groups matching the
standardized profiles.
4.12 Effective weld length.
In a normal type of weld, so-called "end down-slopes" are formed. They result in weakening of the
section at the weld's beginning and end. The effective weld length will then be smaller than the
actual length (reduced by a worse-quality weld beginning and end). For more accurate
calculations, we therefore recommend controlling the load-bearing capacity of welds only for that
part (length) of the weld that has a rated section.
Check this switch in order to consider only the effective weld length during the strength checks of
the connection. The program will set the effective length automatically from the specified
dimensions. If the check box is unchecked, the load-bearing capacity of the weld will be
calculated directly for the dimensions of the connection set in paragraph [4.2].
Recommendation: The calculations using the effective length for the weld control err to the
side of safety. Therefore, the switch should preferably be on constantly. Exceptions include cases
when the weld is provided with special treatment (see the figure) or if it is impossible to use the
automatic calculation for the effective length setting (e.g. for intermittent welds).
As is obvious from the picture, the stress in the upper weld acts in the direction of the tear of the
beam and has the character of tensile stress. The stress in the lower weld will then have the
character of compression stress. In the welds symmetrical along the neutral axis, the value of
both stresses will be the same; in the asymmetrical welds, the values of compression stress may
be higher. In view of the load-bearing capacity of the welded connection, however, the tensile
stress is usually more important for beams connected in that way.
In normal calculation, the program assesses the maximum calculated stress regardless of its
direction during the strength checks. By checking this switch, you will suppress the check of
compression (negative) stresses. During the strength checks, the program will assess only the
tensile (positive) stress.
Note: This parameter is insignificant for welds symmetrical along the neutral axis.
4.14 Loading of the connection.
Check the appropriate check boxes to the left of this paragraph to set the respective weld load
combination. Specify the size for the selected loads.
Hint: If you want to establish the maximum permissible load for the respective connection, use
the "max" button located to the right of the respective input field.
4.24 Strength checks of the connection.
If "Basic calculation method" or "Method of conversion coefficients" (see [1.3] or [1.5]) is
used, the strength checks of the connection are performed by comparison of the maximum
calculated theoretical stresses [4.27, 4.28] to the yield strength of the selected material of the
connection [4.25]. If the connection is to conform, the resulting safety against yield point [4.29]
must be higher than the safety required ([1.4] or [1.6]).
If "Method of permissible stresses" (see [1.7]) is used for calculation, the strength checks of
the connection will be performed by comparison of the maximum calculated theoretical stresses
[4.27, 4.28] to the permissible stress [4.26]. If the connection is to conform, the resulting safety
rate [4.29] must be higher than the safety required [1.8].
Hint 1: You can find the minimum safety values in the respective notes for paragraph [1.2] or in
the theoretical part of the Help.
Hint 2: If the designed connection does not conform to the strength checks, you can use the
respective "min" button in paragraph [4.2] to find the suitable connection dimension.
4.26 Permissible stress.
If "Method of permissible stresses" (see. [1.7]) is used for the calculation, set the value for
the permissible stress of the connection material on this line. This value is then used for defining
the safety rate [4.29] of the designed connection.
Note: For the remaining two calculation methods (see [1.3], [1.5]), this line is only informative
and the value of the permissible stress is set automatically based on the required safety and the
yield strength of the selected material.
Plug and slot welds are usually used for lap joints. They are not suitable for the transfer of high
forces and are especially not suitable for dynamically loaded connections. The connection is
formed by the weld on walls of circular or oval openings and in the contact surface of the
adjoining part. Plugs and slots of small dimensions are usually fully filled with the weld.
These welds are not suitable for the joining of thicker plates and are usually used for thinner
plates up to approx. 15 mm thick. In view of the stress, slot welds are more preferable due to the
better quality of penetration of the weld root. A better quality of the weld, i.e. better strength
characteristic of the joint, can be achieved by sloped walls of openings.
Designing procedure for the connection:
1. On line [5.1] choose the required connection type.
3. Set the appropriate value for the connection loading on line [5.8].
4. If "Method of permissible stresses" (see. [1.7]) is used, set the permissible stress
value on line [5.11].
6. If you want to optimize the connection dimensions or the designed connection does not
comply with the strength checks, use the "min" buttons in paragraph [5.2] to find the
suitable connection dimensions.
7. If you want to establish the maximum admissible load for the respective connection, use
the "max" button on line [5.8].
Hint: Detailed information on the plug weld calculation can be found in the theoretical part of the
Help.
5.1 Connection type.
Choose the required type of connection from the drop-down menu.
5.2 Dimensions of the connection.
Use this paragraph to set all required connection dimensions.
Hint 1: You can find the recommended procedures to choose the appropriate weld dimensions in
the theoretical part of the Help.
Hint 2: After any of the "min" buttons located to the right of the input fields are pressed, the
program will find the minimum suitable value of the respective dimension for the respective load,
selected material and required connection safety.
5.7 Loading of the connection.
Set the appropriate value for the connection loading on line [5.8].
Hint: If you want to establish the maximum permissible load for the respective connection, use
the "max" button located to the right of the input field.
5.9 Strength checks of the connection.
If "Basic calculation method" or "Method of conversion coefficients" (see [1.3] or [1.5]) is
used, the strength checks of the connection are performed by comparison of the maximum
calculated theoretical stresses [5.12, 5.13] to the yield strength of the selected material of the
connection [5.10]. If the connection is to conform, the resulting safety against yield point [5.14]
must be higher than the safety required ([1.4] or [1.6]).
If "Method of permissible stresses" (see [1.7]) is used for calculation, the strength checks of
the connection will be performed by comparison of the maximum calculated theoretical stresses
[5.12, 5.13] to the permissible stress [5.11]. If the connection is to conform, the resulting safety
rate [5.14] must be higher than the safety required [1.8].
Hint 1: You can find the minimum safety values in the respective notes for paragraph [1.2] or in
the theoretical part of the Help.
Hint 2: If the designed connection does not conform to the strength checks, you can use the
respective "min" button in paragraph [5.2] to find the suitable connection dimension.
5.11 Permissible stress.
If "Method of permissible stresses" (see. [1.7]) is used for the calculation, set the value for
the permissible stress of the connection material on this line. This value is then used for defining
the safety rate [5.14] of the designed connection.
Note: For the remaining two calculation methods (see [1.3], [1.5]), this line is only informative
and the value of the permissible stress is set automatically based on the required safety and the
yield strength of the selected material.
Spot resistance welds are usually used to connect thin plates and thin-walled parts. They are
especially very useful in lot production. The connections with spot welds are not very appropriate
for transferring high forces. In view of the type of stress, we distinguish two basic types of
connections with spot welds:
- connections with welds stressed in shear (lap joints)
- connections with welds stressed in tear (by tension)
In technical practice, not more than 3 parts with maximum total thickness up to approx. 15 mm
are allowed to be joined for connections with resistance welds. The thickness ratio for individual
parts should not exceed 1:3. The welds should be positioned towards the external force so that
they are always only stressed in shear. Spot welds stressed in tension have significantly lower
load-bearing capacity, which is why their use is not recommended. Lap welds can be made as
single-shear or double-shear. A minimum of 2 and maximum of 5 spot connections should be
located in the direction of acting force.
Designing procedure for the connection:
1. On line [6.1] choose the required connection type.
3. Set the appropriate value for the connection loading on line [6.7].
4. If "Method of permissible stresses" (see. [1.7]) is used, set the permissible stress
value on line [6.10].
6. If you want to optimize the connection dimensions or the designed connection does not
comply with the strength checks, use the "min" buttons in paragraph [6.2] to find the
suitable connection dimensions.
7. If you want to establish the maximum admissible load for the respective connection, use
the "max" button on line [6.7].
Hint: Detailed information on the spot weld calculation can be found in the theoretical part of the
Help.
6.1 Connection type.
Check the switch with the respective image to select the required connection type.
6.2 Dimensions of the connection.
Use this paragraph to set all required connection dimensions.
Hint 1: You can find the recommended procedures to choose the appropriate weld dimensions in
the theoretical part of the Help.
Hint 2: After any of the "min" buttons located to the right of the input fields are pressed, the
program will find the minimum suitable value of the respective dimension for the respective load,
selected material and required connection safety.
6.6 Loading of the connection.
Set the appropriate value for the connection loading on line [6.7].
Hint: If you want to establish the maximum permissible load for the respective connection, use
the "max" button located to the right of the input field.
6.8 Strength checks of the connection.
If "Basic calculation method" or "Method of conversion coefficients" (see [1.3] or [1.5]) is
used, the strength checks of the connection are performed by comparison of the maximum
calculated theoretical stresses [6.11, 6.12] to the yield strength of the selected material of the
connection [6.9]. If the connection is to conform, the resulting safety against yield point [6.13]
must be higher than the safety required ([1.4] or [1.6]).
If "Method of permissible stresses" (see [1.7]) is used for calculation, the strength checks of
the connection will be performed by comparison of the maximum calculated theoretical stresses
[6.11, 6.12] to the permissible stress [6.10]. If the connection is to conform, the resulting safety
rate [6.13] must be higher than the safety required [1.8].
Hint 1: You can find the minimum safety values in the respective notes for paragraph [1.2] or in
the theoretical part of the Help.
Hint 2: If the designed connection does not conform to the strength checks, you can use the
respective "min" button in paragraph [6.2] to find the suitable connection dimension.
6.10 Permissible stress.
If "Method of permissible stresses" (see. [1.7]) is used for the calculation, set the value for
the permissible stress of the connection material on this line. This value is then used for defining
the safety rate [6.13] of the designed connection.
Note: For the remaining two calculation methods (see [1.3], [1.5]), this line is only informative
and the value of the permissible stress is set automatically based on the required safety and the
yield strength of the selected material.
which is also applied by the program in "Basic calculation method". If this relation is used, the
permissible tensile stress of the basic material is usually used to define the permissible stress in
the weld section.
The first relation
is used to define the rated stresses in a butt weld section less frequently. This method is used e.g.
in DIN 18800, or for a simplified calculation method according to prEN 1993-1-8. Generally, we
can say that if used, the value of the permissible stress should be derived based on the
permissible stress of the material in shear.
which is also applied by the program in "Basic calculation method". When this relation is used,
the permissible stress in shear of the basic material is usually used to define the permissible
stress in the weld section.
With respect to the established calculation convention (for the sake of the calculation, the load-
bearing weld section is reclined into the plane of connecting the parts), the literature mentions
the second relation for fillet welds only very rarely.
If you still use it, the value of the permissible stress should be derived based on the permissible
tension stress of the material.
Recommendation: This switch should not be used for cases when the total length of the welds
perpendicular to the stress direction is significantly greater than the total length of the welds
parallel to the weld direction. For such welded connections, the calculation will produce
misleading results if the switch is on.
Note: This switch has no meaning for connections with welds located in only one direction.
GMAW TERMS
GMAW Gas Metal Arc Welding, aka MIG (Metal Inert Gas) or Wire Feed Welding
FCAW Flux Cored Arc Welding
AWS American Welding Society
cfh Cubic Feet per Hour (when setting the flowmeter for GMAW and TMAW, you
need a minimum of 20cfh)
psi Pounds per Square Inch
IPM Inches Per Minute (for setting the wire speed on a GMAW welder)
Arc Force The pressure of the welding process
Arc Gap The distance between the tip of the electrode and the metal being welded
Penetration The depth of the weld into the base metal
Porosity Impurities trapped within the weld, usually caused by not enough
shielding gas or dirty base metal.
Stickout How far the wire sticks-out out past the contact tip. Usually no more
than 3/8 an inch for GMAW, and 1-1/2 inch for FCAW.
Travel Speed The rate in which you weld.
Travel Angle 5 to 15 degrees
Gun Angle Perpendicular (90) for a flat weld joint, or half the angle (45 for T-
Fillet, etc.)
Shielding Gasses Commonly used for GMAW is 75% Argon mixed with 25% C0 2, or
100% CO2. For TMAW 100% Ar is used. For Dual Shield FCAW, either a 75/25 mix or
100% CO2 is used.
Dual Shield A welding process that uses Flux Cored wire as well as shielding gas.
Forehand Pushing your welding puddle, giving a shallower penetrating weld.
Backhand Pulling your welding puddle, giving a deeper penetrating weld.
Inert A group of gasses that are non-reactive to other elements. These include
Helium and Argon (Ar is really a Noble gas).
Duty Cycle The percentage of welding time that can be done in relation to the
percentage of time the welder must rest. A 60% duty cycle welder can weld for 6
minutes, but then it must rest for 4 minutes.
FCAW
The flux helps keep the welding process from oxidizing as well as remove impurities from within
the weld.
GMAW
75% Argon and 25% CO2 is a common mixture of shielding gases, as it produces a smooth weld
bead.
100% CO2 is also common as it provides a deeper penetrating weld, however, the appearance
is not as smooth as the 75/25 mixture.
The shielding gas flowmeter needs to be set at 20 cfh (cubic feet per hour).
Dual Shielding
Drag deeper penetration method, also called backhand. 100 is a good angle.
Push Shallower penetration method, also called forehand. 100 is a good angle.
Stickout to 3/8
Excessive Spatter
Caused by:
Excessive Penetration
Caused by:
Burnthrough can also be caused by too much heat and traveling too slow.
Flux Cored Arc Welding
Pluses
Minuses
Pluses
Minuses
MODES OF MIG WELDING
Globular Transfer
Higher Voltage
Mild Steel
Wire only touches the metal at the start, then globs of molten wire are expelled into the
puddle.
Use in the Flat Position only - The globs are BIGGER than the electrode, so gravity is a
problem.
High Amps and High Wire Speed (an example would be 28 volts and 350 ipm)
Can use pure Argon as a shielding gas; gives a higher deposition rate.
High Frequency gives a humming sound, which is desirable.
Globulars are smaller than the electrode, and are deposited at hundreds per second.
This excellerated speed of deposition by the arc force overcomes gravity.
2. Arc Gap: The distance between the end of the electrode and the metal.
4. Porosity: Impurities trapped within the weld (caused by dirty metal or weld
5. Stickout
6. Travel Speed
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List 2 ways to reduce excessive penetration:
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The 4 methods of MIG welding are:
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Give 3 cons (bad things) to SMAW:
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Give 3 pros (good things) to SMAW:
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Give 3 cons (bad things) to GMAW
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Give 3 pros (good things) to GMAW
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