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Contents
COMPRESSION
COMPRESSIO
N
TENSION CROSS SECIONAL
AREA
TENSILE FORCE
CROSS SECTIONAL AREA =P / a
ALLOWABLE TENSILE STRESS
=
UNIT TENSILE
UNIT ELONGATION OR =a / E
STRAIN = STRESS OF
MODULUS
ELASTICITY
TUNGSTEN
S
T STEEL
R
E
CAST IRON
S
S RUBBER
STRAIN
3.5.4. Stress- Strain Curve
3.5.4. Stress- Strain Curve
3.5.4. Stress- Strain Curve
3.5.4. Stress- Strain Curve
3.5.4. Stress- Strain Curve
Plate under bending
Plate under bending
Shaft under torsion
Shear strength
3.5.3. Static And Dynamic Loading
S
T
R
E ENDURANC
E
S
S
N CYCLES OF
STRESS
Endurance limit
Endurance limit
3.5.6. Elevated Temperature Strength
Glass, ordinary 9 5
Glass, pyrex 4 2.2
Quartz, fused 0.59 0.33
Aluminum 24 13
Brass 19 11
Copper 17 9.4
Iron 12 6.7
Steel 13 7.2
Platinum 9 5
Tungsten 4.3 2.4
Gold 14 7.8
Silver 18 10
Coefficient of Thermal expansion
microinch
Unit Name per inch per Fahrenheit degree Symbol SI Equivalent
per Celsius de
gree
m/m-C 1x10-6 /K
per Fahrenheit d
egree
per Kelv /C 1 /K
in
/F 1.8 /K
/K 1 /K
3.5.7. Elevated Temperature Design
A ELASTIC
E EXTENSION
B- CREEP AT
C DECREASING RATE
EXTENSION PER CENT
B D C CREEP AT
APPROXIMATELY
CONSTANT RATE
F D CREEP AT
INCREASING RATE
E ELASTIC
CONTRACTION
F PERMANENT
A CHANGE OF LENGTH
Charpy Toughness(lbin)
Ductile
Behavior
Brittle Transition
Behavior Temperature
Temperature (F)
Material properties
Material properties
3.5.10.Types Of Fractures -- I
Depends on Circumstances
Relatively Superficial in established & Proven
area
Critical application, more wide ranging and profound
range of responsibilities
Designer should also be Cost-conscious
Over Designed Plate/Pipe
Over Sized Fillet weld
Continuous weld when intermittent weld would
suffice
Excess Reinforcement
Expensive welding consumables, etc,.
ControlDesigner
of Distortion ; Communication
must look into this. of design Symbols & Safety St
ANALYSIS OF FAILURES
Strength of the weld depends Double Fillet Welded Double Fillet Joggle Lap Joint
With Backing
Applications of
Plug Weld Joining Two Plates Plug Weld Used to Attach Staybolt in
Plug Welding Pressure Vessel Fabrication
Use Lap & Fillet welds instead of Groove weld if FATIGUE is not a
Welding Calculations
Fundamental
assumptions
Welds are homogeneous and
isotropic elements
Welds are rigid and their
deformations are negligible
Effects of residual stresses,
stress concentrations and
shape of the welds are
neglected in static design.
Varying stress
distribution
along the weld;
the tensile stress
at centre is
greater than the
avg. stress.
Total throat thickness is >
than material thickness
No edge prepn large electrodes, high welding current, high
Welding Calc. . .
Good engineering practice
Failure Plane
Shear stress=Txr/J
A Vertical Shear force caused by the offset load creating a moment about
the mid point between the welds as well as horizontal shear force.
Design the weld size to carry 1/3rd-1/2 of the load capacity of the
BASE METAL CHECKING
Welding Calc. . .
Select joint types that will transmit the service stresses successfully
Welding Calc. . .
Rule Of Thumb Fillet Weld Sizes
The allowable stress is fixed fraction of the shear yield strength of the metal.
metal
Welding Formulae
Welding Formulas
(Reprinted
Reprinted from Design Data, PSG Tech,1995
Weld size
Linear misalignment
Overlap
Calc. maximum acceptable flaw size according to fitness for service principles
Shape Imperfections . .
Lap joints welded with fillet welds
For corner joint where fillet weld is not adequate Bevel both
member
Fatigue of weldments
S/N curves for welded and unwelded specimens
Examples of joint classificn.
from BS 7608
Melt smoothing ;TIG Torch (140% impr.) Fatigue strength of welds does
not depend on the yield and
Introducing Compressive stresses tensile strengths of parent
Shot or grit blasting (25-100% impr.) metal.
Structural discontinuity
UW-15 WELDED CONNECTIONS
Matching CTE
Distribute CTE
over several
interfaces.
Dihedral
x2 y2 z2
Q x, y,z Qf exp
a2f b2 c2
Q x, y,z Qr exp x2 y2 z2
ar2 b2 c2
T2
T3
T1
Thermocouples location
W2
W1
W3
Welding of a T-joint
3.6.1. Typical Types Of Loads
TENSION LOAD
BENDING
ON LOAD
SI
ES
R
MP
CO
SHEAR
LOAD
3.6.2. Types Of Load
STATIC IMPAC
T
VARIABLE
3.6.3. Types Of Joints
WELD
SINGLE T
JOINT DOUBL
CORNE WELD WELD ET
R JOINT JOINT
SQUARE BUTT
JOINT
LAND SPACER
E RIGH WRONG
T
F
BACK GOUGING
3.6.7. SHEAR STRENGTH OF WELD
GIVEN :
Width of the flange= 250 mm. Thickness of the flange =
70 mm
Thickness of the web = 15 mm. 3Depth of the6web =
1200mm
h
Total shear on section = 860 Kn 3
3
Then : r = (V.a.Y)/I.n ( 860/10) x (70 x 250)/10
x 1270/2000
=
{ ( 250/12000) x (1.340 )
2.35 x 1.2 } x 2/12
= 0.2934712 MN/m
If the size of the fillet is w, and allowable shear strength
= 96 MN/m2
Then, 0.707 w x 96 = 0.2934712.
or w = 4.32 mm
3.7.1. Behaviour Of Welded Structures
Under Dynamic Loading
When the load on a member is constantly varying
in value or is repeated at relatively high frequency
or constitutes a complete reversal of stresses
with each operating cycle the materials
endurance limit must be substituted for the
ultimate strength where called for by the design
formula
Under high load values the variable or fatigue
mode of loading reduces the materials effective
ultimate strength as the number of cycles
increases
At a given high stress value the material has a
definite service or fatigue life expressed as n
cycles of operations
3.7.2. ANALYZING THE FATIGUE LOAD
A TYPICAL S aAv+
FATIGUE T
LOAD a
PATTERN
R Av-
CURVE E a a MAX
MIN
S
S
THERE ARE TWO WAYS TO TIM
REPRESENT THE FATIGUE LOAD : E
1. AS A MEAN OR AVERAGE STRESS
WITH A SUPERIMPOSED VARIABLE
STRESS
2. AS A STRESS VARYING FROM A
MAXIMUM VALUE TO A MINIMUM
VALUE . HERE THE CYCLE CAN BE
REPRESENTED BY THE RATIO
K = a Min / a Max
3.7.3. VARIABLE STRESS AND MEAN
STRESS RELATIONSHIP
b
d
f
c e a
a = ULTIMATE STRENGTH UNDER STEADY LOAD (YIELD
STRENGTH)
STRENGTH
b = FATIGUE STRENGTH FOR A COMPLETE REVERSAL OF
STRESS
f = VARIABLE STRESS SUPERIMPOSED ON STEADY STRESS
e = MEAN STRESS ( AVERAGE STRESS )
A LINE CONNECTING POINTS b AND a WILL INDICATE THE
RELATIONSHIP BETWEEN THE VARIABLE STRESS AND THE
MEAN STRESS FOR ANY TYPE OF FATIGUE CYCLE FOR A
RELATIVE FATIGUE STRENGTH
%
80
70
85
90
75
95
100
1
X 100
ALLOWABLE FATIGUE STRESS
KNOWN FATIGUE STRENGTH
2
7
3
ab
N
4
/ N
3.7.4. Fatigue Strength
6
3.7.5. FATIGUE STRENGTH AS RELATED
TO THE NUMBER OF CYCLES
IF , a = FATIGUE STRENGTH FOR N CYCLES
A A
a = FATIGUE STRENGTH FOR N CYCLES
B B
c = 0.13 FOR BUTT WELDS AND
= 0.18 FOR PLATES IN AXIAL LOADING,
TENSION AND
COMPRESSION
c
THEN ,
A B B A
a = a x(N /N )
3.7.6. Improving Fatigue Strength
FILLET WELD 36 w / 50 w / 62 w / 62 w
ALL 1 0.5r 1 0.5r 1 0.5r
3.8.3. STRENGTH OF WELDED JOINT
AND BY :
1 FOR CORNER
AND SLOT
1.3 0.3 x { P(min)/ P(max)} WELDED
JOINTS
PROBLEM xx
100
A PLATE IS ATTACHED TO
THE FRAME OF A MACHINE xxxxxxxxxxxxxxx
AS SHOWN IN THE FIGURE 150 SOLUTION
SHOWN WITH A VERTICAL CONSULTING THE TABLE GIVEN
LOAD OF 45 Kn. TO FIND IN 3.8.2.:
OUT THE SIZE OF THE ALLOWABLE LOAD
FILLET IF THE LIFE OF
5 THE = (50 w)/( 1 0.5r) N /mm
COMPONENT IS 6 x 10 = (50 w)/{1 0,5(-0.3)} N/mm
CYCLES AT = 43.5 w N/mm
P(min)/P(MAX) = -0.30 = 795 N/mm (FOR STATIC
LOADING)
RESULTANT FORCE= 795 HENCE w = 18.3 mm.
N/mm FOR PRACTICAL PURPOSES THE
FILLET SIZE TO BE TAKEN AS
20mm
3.9.1. Design Of Welded Pressure Equipment
a a
WHERE : Z = (a E + p) / ( a E
p)
3.9.3. FORMULAS FOR SHELL THICKNESS
ts = THICKNESS OF THE SHELL IN INCH
rc = MEAN RADIUS OF CIRCUMFERENCE OF THE SHELL IN
INCH
m
r = MEAN RADIUS OF THE MERIDIAN OF THE SHELL IN
INCH
p = INTERNAL PRESSURE IN psi
aa = ALLOWABLE STRESS ( ASME SEC. 8 PAR USC 23 )
Em = JOINT EFFICIENCY ( ASME SEC. 8 PAR UW 12 )
p
acp= TENSILE STRESS IN THE DIRECTION OF THE
MERIDIAN
arp = TENSILE STRESS IN THE DIRECTION OF A TANGENT
TO A
CIRCUMFERENCE
a = TENSILE STRESS IN THE RADIAL DIRECTION
Weld bead profile: Convex or Concave?
Solidification of molten bead leads to shrinkage
Shrinkage of a concave bead leads to tension on surface tends to crack
Shrinkage of a convex bead leads to compression on surface does not crack
Generally, slightly convex beads are preferred.
Lincoln Electric
SUMMARY
PFBR Safety Vessel under erection..
PFBR Safety Vessel under erection..
PFBR Safety Vessel under erection..
CONCLUSION