DESIGN PRINCIPLES &

TYPES OF JOINTS,
MECHANICAL JOINTS &
STIFFERNERS
 DOCUMENTS FOR DESIGN

Codes & Standards

Handbooks
Specification
References
Product Catalogues
 Codes & Standards
1. ASME VIII / IX Boilers and Pressure Vessels
Codes
2. AWS D1.1 Structural welding Codes
3. API 1104 Std for Welding Pipelines and Related
Facilities
4. AWS D15.1 Railroad Welding Specifications for
Cars and Locomotives
5. API 650 Design Standard for Welded Steel
Tanks for Oil and Fuel storage.
 DESIGN PRINCIPLES OF WELDED JOINTS

Consideration on weld design

(1) Determination of Load Conditions

a) Torque: shaft, revolving part

b) Forces on members: dead weight of parts
c) Maximum load on members: crane hoist, shovel, lift track, material handling
equipment
d) Maximum strength: cables
e) Shear force: pin
f) Frequency of applied load: cranes, railway bridges, vibrating machines/
equipment
 DESIGN PRINCIPLES OF WELDED JOINTS
Consideration on weld design
(2) Major Design Factors

a) Strength and stiffness

b) Safety factor
c) Good appearance
d) Deep, symmetrical sections to resist bending
e) Welding the end of beams rigidly
f) Rigidity with welded stiffeners to minimize the weight of material
g) Tubular sections or diagonal bracing for torsion loading
h) Standard rolled sections, plate, and bar for economy and availability
i) Accessibility for maintenance
j) Standard, commercially available components specified by index tables,
k) way units, heads, and columns
 DESIGN PRINCIPLES OF WELDED JOINTS

Consideration on weld design

(3) Designing The Weldment

3.1 General Points for effective design

a) Easy handling of materials, inexpensive tooling, and accessibility of the

joints
b) Check with the shop for ideas to cost savings
c) Establish realistic tolerances based on end use and suitability for
service Minimize the number of pieces to reduce assembly time and
the amount of welding
 DESIGN PRINCIPLES OF WELDED JOINTS
Consideration on weld design

3.2 Part Preparation

a) Select appropriate method for available material and equipment and

the relative cost.

Method: Thermal cutting, Shearing, Sawing, Blanking, Nibbling,

Machining. Back weld preparation: Air carbon arc gouging, Oxygen
gouging, Chipping
 DESIGN PRINCIPLES OF WELDED JOINTS
Consideration on weld design
3.4 Forming

Factors to choose forming method:

a) Base metal composition

b) Part thickness
c) Over-all dimensions Production volume Tolerances
d) Cost
e) Cold forming reduces the ductility and increase the yield strength of
metals.

Generally, the relevant standard provides maximum cold forming allowances.

For example, Section VIII of the ASME Boiler and Pressure Vessel Code requires
under certain circumstances cold forming that results in extreme fiber elongation
over 5 % in plates must be stress relieved.
 DESIGN PRINCIPLES OF WELDED JOINTS
Consideration on weld design

3.5 Weld Joint Design

Should be selected primarily on the basis of load requirement.

However variables in design and layout can substantially affect costs.
The application of general rules is mandatory.

3.6 Size and Amount of Weld

Over design is a common error, as is over-welding in production.

Control of weld size begins with design, but it must be maintained
during the assembly and welding operations.
 DESIGN PRINCIPLES OF WELDED JOINTS

(4) Basic guides for control the size and amount of welds:

a) Adequate but minimum size and length should be specified.

Oversize welds: causes excessive distortion and higher residual stress increases cost
The size of fillet weld is important because the amount of weld required increases as the
square of the weld size increases.

b) Continuous fillet weld is preferable to intermittent fillet weld. It is less

costly, and there are fewer weld terminations that are potential sites of
discontinuities.

c) Intermittent fillet weld is used when static load conditions do not

require continuous weld. This weld should not be used under cyclic
loading conditions.
 DESIGN PRINCIPLES OF WELDED JOINTS
(4) Basic guides for control the size and amount of welds:

d). To derive maximum advantage of automatic welding, it may be better to

use one continuous weld rather than several short welds

e) The weld should be placed in the section of least thickness, and the
weld size should be based on the load of that section.

f) Welding of stiffeners and diaphragms should be limited to that required

to carry the load, and should be based on expected out-of-plane
distortion of the supported components under service loads as well as
during shipment and handling.

g) The amount of welding should be kept to a minimum to limit distortion

and internal stresses and, thus, the need and cost for stress-relieving
and straightening.
 DESIGN PRINCIPLES OF WELDED JOINTS
(5) Subassemblies
In visualizing assembly procedures, the weldment into subassemblies
in several ways could offer the greatest cost savings. The following are
advantages of subassemblies:

a) Several subassemblies can be worked on simultaneously.

b) Better access for welding can be provided, and automatic
welding may be permitted.
c) Distortion may be easier to control.
d) Large size welds may be deposited under lesser restraint with
minimizing residual stresses in the completed weldment.
 DESIGN PRINCIPLES OF WELDED JOINTS
(5) Subassemblies

e) Machining of subassemblies to close tolerances can be done

before final assembly. If necessary, PWHT can be performed
before final assembly.
f) Chamber compartment can be leak tested and painted before final
assembly.
g) In-process inspection and repair is facilitated.
g) Handling costs may be much lower.

When possible, it is desirable to construct the weldment from standard

sections, so that the welding of each can be balanced about the neutral axis.
 DESIGN PRINCIPLES OF WELDED JOINTS
(6) Welding Procedures
The following guidelines can be effective in weldment design:

a) Flat position in welding is preferable for Quality, Cost, and Delivery.

b) Joint design requiring welding only from one side should be
considered to avoid manipulation or overhead welding.
c) Backing strips increase the speed of welding for the first pass in
groove weld.
d) The use of low hydrogen electrodes or welding processes
eliminates or reduces preheat requirements.
e) Reinforcement of a weld is generally unnecessary to obtain a full-
strength joint.
 DESIGN PRINCIPLES OF WELDED JOINTS

(6) Welding Procedures

f) With T-joints in thick plate, lamellar tearing should be avoided

using a material with improved mechanical properties for
through-thickness directions.

g) Joints in thick sections should be welded under conditions of

least restraint; for example, prior to installation of stiffeners.

h) Sequencing of fit up, fixturing, and welding is important for box

members made of plates, because correction of distortion after
completion of welding is virtually impossible.
Basic design of weld joint -static loading-
Basic design of weld joint -static loading-
Basic design of weld joint -static loading-
 TYPES OF WELDED JOINTS
A joint is a junction of the members or the edges of the members that are
to be joined or have been joined. The five basic joints used in welding
and brazing design are;

a) Butt
b) Corner
c) T
d) lap
e) Edge

Schematic illustrations of these joints are presented in Figure 8.1.

 Calculation of weld strength

Any weld joint in a structure should furnish enough strength to

withstand any anticipated static or dynamic load.

When PWHT is specified, the base metal and weld materials should be
chosen carefully to ensure required structural strength.

Structures for public use should be built carefully in accordance with

applicable rules, provisions, and/or specifications.

Considerations to ease of welding, the possibility of future non-

destructive tests, and future repair operations are always necessary,
and step-by-step communication between designers and
production/welding engineers is also essential.
Load and stress on weld joint
Throat thickness of full penetration
groove joint
Throat thickness of fillet weld
(Fillet weld with equal leg length)
Throat thickness of fillet weld
(Fillet weld with unequal leg length)
Required weld size for fillet joint
Shear stress distribution of fillet weld
Effective length of weld
Allowable stress in basic design
-normal stress and shear stress-
Allowable stress
Basic design flow of static loading
Summary
Required weld size for fillet joint
 MECHANICAL JOINTS

A mechanical joint is a part of a machine which is

used to connect another mechanical part or
mechanism. Mechanical joints may be temporary or
permanent.

Most types are designed to be disassembled when

required. Mechanical joints are much cheaper and are
usually bought ready assembled.
 MECHANICAL JOINTS
Bolted Joint
A bolted joint is the most common temporary joint used in the
design of a system or machine. Like the name of the joint states,
the joint uses a bolt and screw to connect the two parts.

The size of the bolt is determined by the load required to ensure

the connection is not severed during operation of the system.

A bolt is inserted through a non-threaded hole drilled to the

desired or engineered design and then a nut with washer is
screwed on the end of the bolt.

This type of joint allows the maintenance department to easily

disassemble the joint when necessary.
 MECHANICAL JOINTS
Bolted joints are one of the most common elements in
construction and machine design. They consist of fasteners that
capture and join other parts, and are secured with the mating of
screw threads.

There are two main types of bolted joint designs. In one method the
bolt is tightened to a calculated clamp load, usually by applying a
measured torque load.

The joint will be designed such that the clamp load is never
overcome by the forces acting on the joint (and therefore the joined
parts see no relative motion).
BASIS FOR DESIGN RECOMMENDATIONS

The behavior of individual fasteners

subjected to different types of loading
forms a basis for developing design
recommendations.
 Bolts Subjected to Tension
The tensile capacity of a fastener is equal to the product of the stress
area As and its tensile strength u. However, it is convenient for design
purposes to specify permissible forces and stresses on the basis of the
nominal area of the bolt Ab rather than on the stress area As . Such a
transformation is readily performed because the ratio of the stress area
to the nominal bolt area only varies from 0.75 for -in. diameter bolts to
0.79 for l 1/8-in. diameter bolts. The maximum tensile load Bu of a
fastener is given as

Expressed in terms of the nominal bolt area and using the lower bound,

For most bolt diameters, Eq. 4.3 yields a slightly conservative estimate of
the tensile capacity of a bolt.
 Bolts Subjected to Shear
The tension-type shear test was observed to provide a lower bound
shear strength. The shear strength (in kilopounds per square inch) of a
fastener was found to be independent of the bolt grade and equal to
62% of the tensile strength of the bolt material; hence

The shear resistance of a bolt is directly proportional to the available

shear and the number of shear planes. If a total of m shear planes
pass through the bolt shank, the maximum shear resistance Su of the
bolt is equal to
 Bolts Subjected to Shear
When shear planes pass through the threaded portion of the bolt, the
shear area is equal to the root area of the bolt, which is about 70 to
75% of the nominal bolt area. A lower bound to the maximum shear
capacity of the bolt can be expressed as

If one shear plane passes through the shank of the bolt and one
passes through the threads, the total shear area is equal to the sum of
the individual components.
 Screw Joint
A screw joint is another temporary joint used to assemble two
connections.

This type of joint utilizes a screw only and is inserted through a

drilled hole of one arm of the connection. The other arm or
connection point is drilled to the desired size and then tapped
with a device that threads the hole to the same size as the
screw.

The screw is then inserted and tightened down through the

drilled arm and into the tapped hole of the other arm of the
connection. A screw joint is commonly used in soft metal
connections so wear can easily be repaired, such as in
aluminum joints.
GUSSET PLATE
 GUSSET PLATE
Gusset plates are thick sheets of steel that are used
to connect beams and girders to columns or to
connect truss members.
A gusset plate can be fastened to a permanent
member either by bolts, rivets or welding or a
combination of the three.
Gusset plates not only serve as a method of joining
steel members together but they also strengthen the
joint.
They can be used in bridges and buildings along
with other structures.
 GUSSET PLATE
Gusset plates can be made into a variety of shapes and sizes
from a range of materials. These calculations are made based
upon the forces and loads applied to the gusset plate through
the nearby steel components.

A gusset plate can be either the only connection method or it

can be used in conjunction with bolts or welds.

Gusset plates are usually square or rectangular, but can be

triangular or made into a customized shape to fit the joint. The
shape of each plate is designed so that welding or bolts can be
applied to different edges of the plate.
 GUSSET PLATE
There are several different prominent connection types that
include gusset plates which include KT gusset plate, uniform
force bracing connection, and bolt group

A KT gusset plate connects several members together through

one gusset plate. The gusset plate is welded to a beam and
then two or three columns, beams, or truss chord are connect
to the other side of the gusset plate through bolts or welds.

A uniform force bracing connection connects a beam, column,

and one other member. The gusset plate is bolted to the
column and welded to the beam. The connection of the last
remaining member can be through either bolts or welds.
THE END