MACHINE DESIGN - An Integrated Approach, 4th Ed.

Example 16-4-1

EXAMPLE 16-4

Design of a Dynamically Loaded Weldment Assembly

Problem: The weldment assembly in Figure 16-17 has fillet welds all around between the pipe and each end plate.
Determine the weld size needed to withstand a dynamic load that varies between Fmin = -80 lb and Fmax
= 600 lb for infinite life with a fatigue safety factor Nfr  1.5.

Given: The material is ASTM A36 structural steel and an E70xx welding electrode is used. The Schedule 80
pipe is 4.5-in OD by 0.337-in wall (3.83-in ID). Dimension a = 15 in and r = 10 in.
Pipe dimensions: OD  4.5 in wall  0.337  in
Electrode strength Exx  70 ksi
Applied loads Fmin   80 lbf Fmax  600  lbf
A36 yield strength Sy  36 ksi
Weldment dims a  15 in r  10 in

Assumptions: The weldment is a Category C but the weld may limit as Category F.
Solution: See Figure 16-17 and Mathcad file EX1604.

1. Failure due to dynamic loading of weldments has been shown to depend only on the stress range or oscillation between the
minimum and maximum values of stress seen during the cycle.[2] The force range is Fmax – Fmin = 600 –(–80) = 680 lb.

Force range P  Fmax  Fmin P  680 lbf

2. This is Case 9 in Figure 16-16, which shows the direct shear component factor Aw = πd. Use this to find the unit load fs at
point A due to direct shear.
d  OD d  4.5 in Aw  π d Aw  14.137 in
P lbf
fs  fs  48.1 (a)
Aw in

3. Find the unit load fb at point A due to the bending moment using Sw from Case 9.

Bending moment M  P a M  10200  lbf  in

2
π d 2
Sw from Case 9 Sw  Sw  15.904 in
4
M lbf
Unit bending load fb  fb  641.3  (b)
Sw in

4. Find the unit load ft at point A due to the torsional moment using Jw from Case 9.

Torque T  P r T  6800 lbf  in

3
π d 3
Jw from Case 9 Jw  Jw  71.569 in
4
T d lbf
Unit torsion load ft  ft  213.8  (c)
2  Jw in

5. Find the magnitude of the resultant force at point A (the maximum weld load).

2 2 2 lbf
FR  fs  fb  ft FR  678  (d)
in
This is the load per inch of weld length.

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MACHINE DESIGN - An Integrated Approach, 4th Ed. Example 16-4-2

6. From Table 16.2a, a Category F joint has a shear stress-range endurance strength Sers  8  ksi. Apply the safety factor to this
strength to get an allowable stress.

Sers
Allowable stress τallow  τallow  5333 psi (e)
Nfr

7. The throat area of one linear inch of weld length is equal to the throat dimension. So, if we set the throat stress equal to the
allowable value from equation (e), use this unit load and calculate the unit area needed to achieve that allowable stress, we
will define the required throat dimension.

FR 2
in
Minimum throat dim t  t  0.127  (f)
τallow in

8. This is the throat dimension, but fillet welds are specified by their leg dimension. Assuming an equal-leg fillet in a 90joint,
the leg dimension will be:

t
Leg dimension w  w  0.180 in (g)
cos( 45 deg)

9. Specify a 3/16” fillet weld. This meets the minimum weld size specified in Table 16-2 and will have a safety factor of
approximately 2.5 based on equation 16.1.

10. The weld between the pipe and arm is stressed at a lower level than the weld at A because the bending moment is zero at the
end of the cantilever. That weld sees only direct shear and torsional shear which are 32% of the stress at A. Table 16-2
specifies a minimum 3/16” weld for this wall thickness and is the same as the other end, which simplifies fabrication.

11. We also need to check that the stress in the fusion area between weld and pipe will not fail. Remember that only the stress
range is of concern with weldments and it is due to the range of force oscillation, here 680 lb from step 1. Find the normal
bending stress range and torsional shear stress range on point A using equations 4.11b and 4.23b respectively.

Inside pipe diameter ID  OD  2  wall ID  3.826 in

Moment of inertia I 
 4
π OD  ID 
4
I  9.61 in
4
64
Pipe outside radius c  0.5 OD c  2.25 in

Polar moment of inertia J 


π OD  ID
4 4
 J  19.221 in
4
32
M c
Normal bending stress σx  σx  2388 psi (h)
I

T c
Torsional shear stress τxz  τxz  796 psi (i)
J
12. Find the maximum shear stress, principal stresses, and von Mises stress that result from this stress combination using
equations 4.6 and 5.7c for σz  0  psi.

2
 σx  σz  2
Maximum shear stress τmax     τxz
 2 

τmax  1435 psi

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MACHINE DESIGN - An Integrated Approach, 4th Ed. Example 16-4-3

σx  σz
Principal stresses σ1   τ max σ1  2629 psi (j)
2
σ2  0  psi

σx  σz
σ3   τ max σ3   241 psi
2

2 2
von Mises stress σ'  σ 1  σ 1 σ 3  σ 3 (k)

σ'  2757 psi

13. Assume this assembly is an AISC Category C. Table 16-5a shows the infinite-life fatigue strength for a Category C weldment
as Sf  10 ksi. The safety factor is then:

Weldment Category C Sf
Nf  Nf  3.63 (l)
safety factor σ'
The weld material limits this design.

EX1604.xmcd