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POSTED ONOCTOBER 18, 2012 BY SHIBASHIS GHOSH

Welding Joint Design Calculation Example for

Fillet weld in Torsion in 10 Steps
The overall procedure explained in the weld design calculation for
bending article will holds good in this article as well with only major
difference is the use of polar moment of inertia (J) instead of the area
moment of inertia (I) since we are talking about torsion here.

Bit confusing? Well, we are going to understand the procedure in detailed

step by step manner here with the following example:

Problem statement: Look at the design of the welded connection below, its

a cantilever kind of structural joint where the fillet welds are subjected to
the torque developed due to the load F. Calculate the fillet weld size required
for the application.

Fillet Weld
Strength Design Calculation in Torsion Example
 

Given,

F= 20000 N

X = 200 mm

Y = 150 mm

Z=100 mm

Solution:

Step-1: Calculate COG: Find out the centre of gravity (COG) of the whole
fillet weld joint scheme. In the example above, we have a rectangular
shaped weld area. So, obviously, the COG will be at the intersection of the
two diagonals of the rectangular. And we can locate the COG , which is
marked as C, as below:

a=Z/2=50 mm

b = Y/2 = 75 mm

Step-2: Calculate the unit throat weld area (Au): The unit throat weld
area for the example problem is:

Au= 2*(Y+Z) = 2*(150+100) = 500 sq.mm

 
Step-3: Calculate unit throat polar moment of inertia (Ju): The polar
moment of inertia of any shape is the sum of the area moment of inertia of
the shape about the XX axis and that of the YY axis. The shape of the
welded joint, in the above example, is rectangular in shape with two sides as
Y and Z respectively.
The equation for calculating the (unit throat length) polar moment of inertia
for rectangular shaped fillet welding connection is,

Ju=(Y+Z)3  /6=(150+100)3  /6 = 2604166.66 mm3

Step-4: Calculate design strength (Pw): The design weld

strength for the material can be calculated using the eq.2 as:

Pw=0.5*fu= 0.5*430 N/mm = 215 Mpa

2

(Assuming ultimate tensile strength of base material as 430 N/mm ) 2

Step-5: Calculate max. Direct shear stress in vertical

direction ( τsv) : Maximum direct shear stress developed in the
welded joint to be determined as:

τs=F/Au=20000/500 = 40 N/mm 2

 
Step-6: Calculate max. Torsional shear stress in horizontal direction
at any corner ( τth) : The reason why the corner point of the weld is
chosen is: the torsional shear stress will be maximum at the corner
because the distance between the corner point and the COG of the
section is maximum.

The torsional shear stress, in general, can be found from the

equation:

τt = (T*r) / Ju……………………………….eq.a

where,

T = applied torque = F*[X+(Y-b)]=20000*[200+(150-

75)]=5500000 N-mm

(refer the picture above)

r = Distance between the point of interest on the weld and the COG
of the section

Now, in case of horizontal torsional shear stress at any corner,

r = a = 50 mm

So, from the eq.a:

τth= (T*r) / Ju = 5500000*50 / 2604166.66 = 105.6 N/mm 2

 

Step-7: Calculate max. Torsional shear stress in vertical

direction at any corner (τtv) : The above eq.a will be used again
here:

In case of vertical torsional shear stress at any corner:

r = b = 75 mm

So, from the eq.a:

τtv= (T*r) / Ju = 5500000*75 / 2604166.66 = 158.4 N/mm 2

Step-8: Calculate the Resultant shear stress at corner (τ):

Resultant shear stress (τ) = √ [(total horizontal shear

stress) + (total vertical shear stress) ]
2  2

…………………………….eq.b

For the above example,

 
Total horizontal shear stress = τth= 105.6 N/mm 2

Total vertical shear stress = τsv + τtv = 40 + 105.6 = 145.6

N/mm2

So, from the eq.b,

Resultant shear stress (τ) = √ [ 105.6  + 145.6   ] =

2  2

179.86 N/mm2

Step-9: Calculate the weld throat size (t): Use the eq.6 from

the previous article here:

t= τ/Pw  =179.86 / 215 = 0.83 mm

Step-10: Calculate weld leg size (L) : Use the eq.7 of previous

article as below,

L=1.414*t = 1.414*0.83 = 1.173 mm

 
Finally, we obtained the required weld size (leg length) as 3 mm ( next to
1.173 mm as calculated) as the result of the fillet weld design calculation
example. The calculation is done based on the weld stress method discussed
in BS 5950.

NOVEMBER 26, 2012 AT 6:17 AM

there is a mistake in the calculation of weld inertia. L should be 100+2×150