MACHINE DESIGN - An Integrated Approach, 4th Ed.

Example 16-2-1

EXAMPLE 16-2

Design of a Dynamically-Loaded Fillet Weld

Problem: The welded tee section of Figure 16-11 is going to be loaded dynamically with repeated stress ranging
from zero to a maximum. Determine the largest repeated tensile load that the welds can safely
withstand for infinite life with a fatigue safety factor Nfrs  1.5.

Given: The tee is 0.5-in-thick by 4-in wide ASTM A36 hot-rolled steel on both legs, and has 3/16-in fillet welds
full length on both sides. This matches the minimum weld size specified in Table 16-2.
Tee-section dimensions: T  0.5 in L  4  in
Weld leg w  0.1875 in

Assumptions: Matching strength electrode material was used. Shear stress in the weld throat governs the design
(see Example 16-1). The load is evenly distributed along the weld length.

Solution: See Mathcad file Example EX1602.

1.. A repeated stress will range from zero to a maximum value each cycle. Adapting equation 6.1a, the shear stress range Δtis

Δt = τmax  τmin = τmax (a)

2. The geometry of this weldment is similar to that of Figure 16-13e. Note C in Figure 16-13e indicates that this part is a category
C based on its thickness. However, this design has the welds taking the load directly. In that case we must use the fatigue
strength for category F, the weld metal itself, in the weld throat area. From Table 16-5, the tensile stress range endurance
strength Sers for category F and infinite life is S ers  8  ksi.

3. Calculate an allowable shear stress range based on Sers and the desired safety factor.

S ers
τallow  τallow  5333 psi (b)
Nfrs

4. The part as designed has two 4-in-long 3/16-in-leg fillet welds. We need the throat area for this calculation which is 0.707 as
wide as the leg. The load to create the allowable shear stress from equation 4.9 is then:

2
Ashear  2  L w cos( 45 deg) Ashear  1.061 in
Pmax  τallow Ashear Pmax  5657 lbf (c)
5. Check that the fusion area of weld to base metal is safe. The most likely point of failure is at the weld toe. The weld leg area
rather than throat area is used here.
2
Afusion  2  L w Afusion  1.5 in

Pmax
σtoe  σtoe  3771 psi (d)
Afusion

S er
From Table 16-5a, the endurance limit for a Category C weldment is S er  10 ksi . This has a safety factor of Nf  ,
σtoe
Nf  2.65 so the weld throat limits the design, which is typical in fillet welds.

6. We still need to check that this repeated load will not fail the part statically or in fatigue at locations away from the welds.
For example, a Goodman line analysis (Chapter 6) should be done for this repeated load applied to the smallest tensile area
across the centerline of the 1-in-dia hole and for the tearout shear areas of the same hole. Any fasteners used to attach the
base will need to be checked for fatigue under their applied preload (Chapter 15). These tasks are left to the reader.

EX1602.xmcd