394 Design of Machine Elements Design of Welded Sons oe 15x10° _ 1337, 1 Na? © Solution: Bending aes, Oo" TT" Tigv7 Th h This problem canbe solved by the following two methods: Resultant ses, cording o mame shear srs theory Method 1 : : rows PSG 113, he ses induced in this type of welding Leafy ,,,(2 toa beer = 2 (BP 66M, oe HE) ool E) goats aD enss . ar 2285 vin? 566.5410 ot 170 = ee! a=) f hx Rx50? i ) ‘Alowable shear ses inthe veld material oe om smokin tress 125 7 j= BBL ste 125 125 actorof fey 16 Method 2: Equating this Teac with the allowable shear stress of 78.125Nhun* mans 2 572.85 7125 =8.6mm Say Sum Ans, Result: ‘The weld siza, = 9mm A manual winch for a sailing ship is shown in fig. 3.5%. The maximum tensile force from the sail during trimming ‘operations is ISKN and ate at a distance of 100mm from the deck plate. A deck plate is welded to the pivot support tem of 50mm diameter as indicated. Determine the required size of filet weld for the support stem to deck plate connection if the allowable shear stress in the weld is 85MPa. Fig. 3.57 ‘The welded joint given ithe problem is subjced to direct shear stress and bending sts Area of weld, A = x Dt= x x 50 x 0.707 x h= 111A mm? P_ 15000 135.5 atin 7 Nm Bonding moment, M, = Px ¢ = 15000 x 100 = 1.5 x 10°N-mm Frow able 32.6 oc PSGDB 11.6 Direct shear stross, t= I weld thickness is considered : (22 orm = PS orth 1388498 Ane My _ 1sx1o _ 1080.54 7,7 Teak Resultant stress, accocding to maximum shear stress theory Bending stress, = 1 2 1 /f10s0.s4 135) _ 356.8 tae tye, eae Eff M8054) 4 (185) 556.8 vie aoa = SEY oY = Sr tis uequetooe sen me 5568 : -SSmum Say Tun Ans. Result: ‘The weld size, h= Tmt3.96. Design of Machine Elemer Bei ees A plate bracket used to support a machine, support plate and a central loading plate, as shown in fig. 3.58. Calculate the necessary size of the fillet weld if the allowable shear stress in the weld is $0MPa. The arrangement should provide a factor of safety of 1.6. assembled using steel angle sections welded to a | orate on supe pate ee ij ston ‘calor Fig. 358 Given data: WY SON MPa FOS = 1.6 To find: Weld size, © Soluion: ‘Tho weld structure given in the problem is subjected to direct shear and bending stresses ‘Area of weld, A= 600 +900 + 50 50-4 50 + 50) x 0.707h A= 1414 om? B_ S0xl0” _ 3536 Direct shear stress, e= Ze ST = SS Bending moment, Ms = P xe 0 x 10 x 1800 = 90 x 10°N-mm L Section modulus, Zp —% » Design of Welded Joins oreo 3.2.7 or PSGDB 11.6 i bed a oon eee wold is considered a fine of unit thickness. Since the structure is oy) 00 ee eee ee weld portion (1, 28.3). Kea | Ret Then the value is multiplied by 2to pot x offal portion Tar" Te hat by= lo, PAUP) + (log * Aah) + (lo, +Aghs) A,= 1x 900 9000? to 0 1 = Snot mm) bd? 1x900° Toy = SL 200 50.75 x 1h vr Bd 50x? Jam fg, = 2S = 4.167 mnt By AIS hy = F—y, =450~450=0 450-0 450m + d= (60.75 x 1084900 C+ (4.187 +50 450%) 4+ (4.167 +80» 450°) 81 x 108 For fill orton ofthe wld stwture Fox =2 = 81 «10° = 162 x 10%mm* 1 Section modulus, Z, © 200 ) y= P8450 thickness of the weld is considered Z = 360004) « 0.707 = 2545208 mn? 4G _ 90x10" 3536. Bendingstes, o9= = og pwn! Resultant stress,3.98 Design of Machine Elements ( blo shear sires, 1= 2 = 3D 4 Sonim” ‘lowable shear stress, ¢= “ESE = FE quating the value of taf the allowable shear stress, 1803 i cf 3s6mm Say donme 50 Result: Weld sizo, h= 4mm 1A fabricated sel bracket frms th suppor fora machine hosting system as shown in fig 3:0 snd const of two boted connections and a welded pate connection. Calculate the required filet weld sie forthe 30mm thick plate o baseplate connection i the allowable shear tet in the weld is 20M 15} (2st) To find: Weld size, h Design of Welded Joints 3.99 © Solution: From table 3.2.4 ar PSGDB 11.3, for this typeof weld 424PL _ 424x250? «280 ae Pol T* Bending stress, = = 28914 vp? OT01P _ O707H25«10" Diret shear stress, r= S77 pets According to maximum shear stress theory, resultant shear stress = 6.8mm say 6.5mm Au. Result: The weld size, b = 6.57 ae aes Apts Stn lng ard 3mm hick is welded aright ane te enor plata by mm fll wld ae shown in fg 46 Catala the manson torque that can be exerted by the plate if the permissible shear stress in weld material is 45N/mu’. Given data: Length of weld, /= 500mm Size of weld, h= 12mm Permissible shear stress, t= 43N/inum? To find: Maximum torque exerted, Mr3.100 Design of Machine Elements Design of Welded Joints aor @ Solution: = AGB AB = JGO) +50" = 583mm From table 3.2.4 or PSGDB 11.3, (e0y Maximum shear stress on this type of joint, core = FF, 30 424M, we 42a, © Gyr BM.=31.76 x 10Nmm =31.76<10Nm Ams Result: ‘Maximum torque that can be exerted, Mi= 31.76 x 10°Nem A bracket shown ie fig. 3.62 caries a load of IOKN. Find the size of the weld ifthe allowable shear stress is not to exceed 75N/mm’. [MU ~Apr'97] Given data: Load, P= 1OLN= 10 10 Allowable shear stress, = 75Ninan?* To find: Size of the wold, © Solution: Azea of the wold, Fig 3.62, A= 2x 0.707 hx f= 2 0.707 x hx 60 = 84.84xh mn? Primary or droet shear stress, Lond(P) _ 10x10" _ 117.8689 ‘Area(d) MR Ninn? seen «= 2120-1500 ‘Twisting moment, M,~P x e= 10 « 10° x 150 = 1S00000N-mm = St eosias a3 From table 3.2.7 or PSGDB 11.5 Polar moments tinea, J» #2384") ‘ jp _ CP 060), rope Ee reoror a 6 Jo 237552 emt Xr _ 1500000%58.3 _ 368.1299 Secondary sess, 2 1500000583, te 237852 A Nooo Resultant stress, ¢= he 587mm say, 6mm Ans. u Result: Size ofthe weld, = Gam A plate of 200mm width and Oda long is welded to a vertical plate by placing it on tke vertical place to form a cantilever with projecting length of 480mm and overlap between the lates as 120nan. Fillet welds done onal thee sdes A vertical load 30kN sapped athe fee nd ofthe cantilever plat pralel tits wlth of 200m. If the allowable weld stress is 95MPa Determine the weld ise. BU-Now'96) Given data:3.102 Designof Machine Elements ‘With ofthe stot plate, d= 200mm 20 Length ofthe plat, Z = 600mm Projecting length = 48000 Overlap between the plate = 120mm Vertical load, P= 30kN=30 x 10° Allowable weld stress, = 9SMPa = 95 x 10°Nin® = 95mm To find: Size ofthe weld, © Solution: [As discussed in the chapter 3.2.8, thero are two stresses induced in this sytem @ Primary shear stress (1) Gi). Secondary shear stress (x2) due to twisting moment (M) ‘Area of the weld, A =0.70Th (2b + d) = 0.707 x x (2120 +200) = 311 mn? 30x10" _ 964 = 288 Nim 3 1207 = po = 7mm = 33mm Gain 3007 overt, e = 480+ (120 ~N,)=480-+ (120 ~33)= $6 ‘Twisting moment, Mi= P= ¢-=30 % 10? $67 = 17010000 —— AB F = o- wv, F 2 r= (00-33) +1007 ~ 132 548m GB RT i258 From table 3.2.7 (or PSGDB 11.5) and considering the thickness of weld ‘t’, the polar moments of inerti, r= 0B AB = 0,656 Design of Welded Joints 3.103 2 2bed [2% rea] tH [ese 120° (20. 2007 soe orem [#2 0.7074} 2649407 Sh Sccondary sess, = MX? 17010000%132.548 $1 J,” 2689407 Sh Resultant strss, v= fr} 423 + 25,5,Coxd Sh mm? 6s 7 b= EN este pm Aa Result: Size of the weld, = 10mm "Calculate the value of P, ifthe weld size is ‘15mm and the allowable stress is not to exceed 80Nimm. (w-0e 97] Given dat Load = P Weld size, b= 15mm Allowable stress, ¢ = 80Nimm? Tofind: The load, P| © Solution: Arca of weld, A= 0.707 h (2+ d) Fig. 3.64. = 0,707 « 15 x 2 150-+200) = $302.50? fete Por s8610 Winn? Primary shone stress, = “Area 330233104 Design of Machine Elements Ecconticity,¢= 400 +150 Ny From table 3.2.7 (or PSGDB 11.5) Nyx = On asm Bid ~ Quiso)s200 = 400 + (150—45) = 505m ‘Twisting moment,M/=P x e= Px 505 =505P Nm oo aa a 05 +1007 = 145mm GB 10s cosg= Bo M2 wo704 rus (-00=150-N, 150-45 «10Snn) M, Secondary shear stress, = Polar moments of inertia bs? Besa) |* i ab+d he [esueezor ss s0 207) aro eta 2 25150200 Jue = 52008687.Smmm% 505 PS 20086875 Resultant ses, [rah 42,1, cos [iasenao™ of «Gaon cio pf «2x 686.10" P) eG aonn10P)o724 80" 1.549% 10°P Nim? 408 x 10°P Ninn? P=51639.7N= SL.64kN Ans. ct Result: Load, P= 51.64N Design of Welded Joints 40s A eae A route board of a resaurant placed on the platform has the dimensions indicated as shown in ‘fig 365. Ditto wid presure effects a masinum horizontal load of 4RN is considered to apply athe centre ofthe sgn. The vera supporting column consists ofa 100 mim aside diameter pipe and is welded to a base plate, Determine the necessary weld site for the count bate plate connection. Toke + SMP © Solution: ‘The structure given inthe problem is subjected to direct shear, secondary shear as well as bending seca Direct shear ss, cou! hn 4 4000 mda 1000 TAOOO7ET eters kn Ba = Winn ih From table 3.2.3, or PSGDB 11.3, when the structure is subjected to the Fig. 3.65. twisting moment only, the secondary shear stress aw 28M, _ 2.83%4000%1000 RD? x hxl00? 360,32 h Myxer "Note: scan also be calculated by using the relation, Resultant shear stress due tory and 3 af 36032)" _ 3606 a 73.105 Design of Machine Elements From table 3.2.3. or PSGDB 11.3, when the structure is subjected to the bending ‘moment only, the bending stress 566M, ADP 5.85 %.4000%3500, ( 3+ f.35m=2500nn) xt OO" ee 2 M, Note: c can also be caleulted by using the equation o = ‘According te maximum shear stress theory, the resultant stress due to and cis HE) 4 toe a 3 _bu2 tne OY Equting this val fo the given + value wiz = BLD fi h n= 15.4mm say 16mm Ans, 3 Result: ‘The weld size, A~ 6mm ‘The 50 mm square arm is connected to the flange plate via a continuous fillet weld. Determine the minimum weld size for the square arm to flange plate connection assuming the vertical load Of LIKN ifthe allowable shear stress in the weld is 75MPa, Design of Welded Joints Fig. 3.66 Solutions The wel rst gon in he beni eel te lowing ee 1) Dishes dtl 124 1) Sony wr es den tvising moment (1:22 20m) i) Bogs bing mom (1.27 4500m) Dirctser sens o> Be ge HHO 8 A” Boxa)0707 "i M,xr Secondary shear stress, t= “wistng monet Mi Pe; = 1200 x 200 = 2400008 From able 3.27. or PSGDB 1.6, for rectangular section, jn Ge 6 A wold thickest considered bea) Jee 6 <0.707h = GOS 0.707h= 11783334 307Design of Machine Elements Tho diane, r= faBPaac = seas" =3535 = 240000%35.35 72 yi, T7s333h he mes Pxe, Resultant shoar stress, «= Ms Bending tess, o»= Z. from table 3.2.7 or PSGDB 11.6 If thickness of weld is considered 2e=(niadS jorera z (oso fo 07h Z,= 2356.67 gy= 1200x450 _ 229, 6" 735667 ‘The resultant stress du to + and op according to maximum shear stress theory. psy _ 2 7 a 1 Io Feae = pie [= h Enquating this tgac With the value of given in problem am 5-2 A = 36mm — say dmm An. Result: ‘Weld size, = 4mm Design of Welded Joints RSS The suspension stub al essen fora wehice trailer ie shown nf. 267. The whet reaction each sub ae SKN. The suspension assembly soled rectly ont the chas by means of four bolts, whist « 30min, diameter circular section is welded onto the suspension bracket Calulatethe weld sze‘W required f the permis shear sires in the welds 00MP © Solution: ‘The weld structure given in the problem is subjected tothe following stressos (Direct shear sess due to load 15k (Gi) Secondary shear stress due to twisting moment (1,54 x 305mm) (Gi) Bending stress due to bending moment (1.SEN « 400m) P_ 1500 | _1300 225 Ditet shear ess, = 2 tt = Nin? st A mxDt x30x0.107A b bs Secondary shear stess due to twisting moment can be calculated from the equation given in able 3.2.3. or PSGDB 11.3 (considering only Mon the structure) 283M, 4579 naa 2,83%1500%305 RD x h : Ninn x30? "Note: 4 an also be calculated by the equation t2 Resultant shear stress due to rand tis BY PY tne3.10 Design of Machine Elemenis ‘Bending stess due to bonding moment can be calculated from the equation given in able 3.23. or PSGDB 11.3 (considering omly Ms on the structare) 366i, conts0400 De x30? xm = 2? ih ‘According fo maxiaurn shear stress theary, the resultant stress due to and eis ae (ay (Sey Eaquatng ths tp value with the given valu of 100MPa 755.54 too = 554 a A= 788mm say Som Ans. A circular bar is welded to a steel plate as shown in fig. 3.68. The maximum load 1SKN is “applied repetitiously. Determine the size of weld required for 10,000,000 cycles. Design of Welded Joints Sud © Satin: "The odin tesa profes det sha ada eng adn he jon Diet sheets 20 P___ = SHI? ise, “reaoftd “axa (etdisreted ane, = 11936 fom Tobe 3.24 0 FSGDB 11.4, fr lar coe eton 2-7 olds wate sine) My. Pxe _ 15x10 Bending stress, oy = 2b wx PE. 15x10°x250 Ze Ey Raye 4 = 2984N/inm Resultant stress sto drct shear and bending soos tea foroe = (Gonay G93 =2986:38¥/mm ‘The maximum sttess varies fiom 298638nm in one direction to 2986:38Minm in the opposite direction, ‘The allowable fatigue foree’mm for 2,000,000 eycles is 8914 i or 1537.6N/nm vshichever is less. 1 since the load is completely reversed, sole ‘The allowable Gag ores por mi of wld fOr 10,000,000 eyes is 2,000,000 = 482Ninm ‘The weld size can be obained by dividing maximum shear sizes to allowable fatigue force por mi of weld 298638 482 = 594.27N/imm J" 6 e201 forbatin) = 6.19 say 65mm Ans. Result: ‘The weld size, = 6 Smum32 Design of Machine Elements Leone eee Ee CHAPTER -3.3, 3.3. BONDED JOINTS — 3.3.4. INTRODUCTION Bonding with adhesives, is 2 very popular method of joining, whose history dates back to 3000 years. It finds application in assembly technologies very rapidly and extensively, some of them being Iabeling, packing, book binding and footwae. It’s usefelness came into light during ‘World War Il when it wae applied for assembling of load bearing components in sierafs. 3.3.2, ADHESIVES. Adhesive is « filler material that binds pats together. It is a non-metallic substance, mostly a polymer. The parts being joined are called “achenands’ ‘Types of adhesives ‘Adhesives are very many in number, They can be classified as follows. 1 According to thelr function 4, Structural adhesives ‘These perform the mechanical load bearing function (e.g Thiokol - automobile rear window adhesives) ’. Holding adhesives “These can, bear only Himited loads, but mainly form unstressed joints. (e.g House hold appliance) «. Sealing adhesives Perform the fimction of excluding gases or liquids from a joint. (e.g Caulking components). 2. According to chemical structure a, Natural adhesives (Starch, Dextrin), Design of Bonded Joints us ’. Inorganic adhesives (Sodium siticate, Magnesium oxychloride) ©. Synthetic orpanie adhesives 1) Thermoplastcs. fi) Thermosets 3. According to the parts being jointed. a Metal — metal adhesive b, Metal ~ plastic adhesive, ¢. Plastic ~ glass adhesive. 4. Classification of synthatie orgamie adhesives: & Chemically attractive (@g Polyethylene, epoxies, modified acrylic, phenolics, polyamides) b. Pressure sensitive (e.g, Natural rubber, butyl rubber, nitride rubber, polyacrylates) «©, Hot melt (eg, Polyester, polymides, polyolefins, and other thermoplastic elastomers) 4 Evaporative or ditfusion (e.g. Vinyls, aryles, phenols, synthetic & natural eubber) «©. Blastcally and thermally conductive (c.g. Epoxies, palyurethenes, silicones, Piles such ss silver, copper aluminium and gold are used to get electrical conductivity) 5. High temperature applications (up 260°C) 1, Polyimides. », Polybenaimidsaotes Choosing an adhesive Choice of an adhesive is to be made taking into account various parameters. Some of them areas follows: 1. One-part adhesives are better than twa parts. Two parts may result in improper metering and mixing due to human ignorance or negligence 2. Tape and film adhesives are better than Tiquid and paste systems because of ease of handling, Also shrinkage problems are eliminated, resulting in strong bond 3. Thermal expansion properties of the metals being joined should be given utmost mportance. I diffeence of expansion very is high the bond may fal 4. Better to go for adhesives which are les critical about the cleanliness ofthe surfaces being joined, 5. Adhesives with harmful chemicals are to be avoided to protect human health, 6. A single adhesive cannot perform in the same way in all the eases. An adhesive Which is perfect for metal-metal may not be so for metal-plastic: Table shows some commonly used adhesives for various materials31M Design of Machine Elements Desten of Bonded Jos ae Gas aie 333. JOINT DESIGN ‘Material Adsives generally offer les strong joints compared to welding, brazing, or soldxing. An ‘ABS “Fayesies Epo, Alp onary, Nive — phenali, eoes. | achesive joint in general maj be subjected othe following types of ses. 77 wang | Epo Brow weno, Nslon-opxisspalarctane bbe, 1 Mechanical, 2. Thermal — polystrs, alpha ~ eymoaeyate, polyamides, polyvinyl phenolic, Hacperaiddated alloys acces ses _|_reoren pena cis Adhesive joints experience the following types of stresses due to mechanical ein Tony, cellulose exter, Ving] clone ~ Vinyl atts, pobyanyl va om ® Loading tour, args i 3. Compression 4. Cleavage or pect Gaoniae pen ‘These re shown in fg. 3.69, Copper and te Polyester, Epoxy, Alpha ~eyanoaciiae, polyamides, polyayl : : : F alloys thenokc, olyhydeonvehtr, acrylics Ades I - Fpas, Epa phenol, Alpha -cyamoasg ino, enlace a, oo - vinyl chlovde, vinyl acetate polyvinyl bua, acrylics. ay cpa a ft i “Via corde, vngl aoetate,polyvingl butral, olyiydronpeer, Teision ‘Shear —=— Min oc 80N na whichever sls ivi 2 Minimum stress Where, x — Minimum stress | Kemi spee =~ 1. Since tho load is completely reversed. Tins fatigue strength, 50 vig 2 ‘The fatigue strength for 1,00,000 eyeles is oy, for Weycles: By equating this 6,0 typ 533.956 A f= 19.63mm Say 20mm Ans. 2:3122 Destgn of Machine Elements Result: ‘The weld size, “An eccentrial loaded pat pelted frame as thin fig. 3.77 Design he welded joint “If te tensile stress in the plate should mot exceed 1OON/nt and that in weld is 8ON/men. [Anna univ.- Now-2004 20mm Given data: ‘Maximum stress, = 100N/nn* Maximum load, P= 60RN= 60 x 10°N To find: Design ofthe welded joint (Size of the weld, i) Length ofthe weld atthe top, (Gi) Length ofthe weld atthe bottom, @ Solution: Since the tensile sress inthe plate should not exceed 100N/nm? dhe maximum thickness ‘can be caleulated by using the equation PLP 4 bat 60x10” 100* Hox Sm say Som plate “The size of weld should not exceed the thickness ofthe plats =Smm Aus. ow Design of Bonded Joints 3.123 (Gi) Lengih of the weld atthe top, from table 32.40rPSGDB113) LAM Pxe, _ 1414 60x10? «80 oxhxb 100%5%130 = 104mm ‘Actual length, y= 104.4 + 12.5 Say, Length ofthe weld atthe top, 1e= 17mm Am. (ii) Length of the weld atthe bottom, s (from table 3.2.4 or PSGDB 11.3) 1al4x Pxe, 1 210? x50 oxhxt 3x130 = 65.26nm Actual Length, y= 65:26 + 12.5 = 77.76mm Say, Length of the weld at the bottom, b= Tram Ans, 7G Result: Design ofthe welded joint Size ofthe weld, f= Sian Length ofthe weld atthe top, fy = 117i Length ofthe weld atthe bottom, f, = 78mm A plate 106mm wide and 125mm thik sto be weled to othe plate by means of 0 paral {ler welds. The plates are subjected to toad of SORN. Find te length of the meld so that he sarin snes doesnot exceed 86NIont (Do the caleuations under tats oaing) Una Unis Nov. 2005) 8 Solution: ‘Since the thickness ofthe plate is 12.50m, we choose = 125mm Area of weld, A= 2 0.707 x hic = 2x 0,707 x 125 x1= 17.6751 Allowable shear stress, t= be ‘dra 50x10" 176751 0Stmm Ans.i sign of Machine Element 7) Design of Machine Elements Result: Length of weld on each side, = 51mm 3.5. TWO MARK QUESTIONS AND ANSWERS 1, What are the purposes of screws? (@ To secure members, (@ To transmit power 2. Define: Pitch, Lead. Pitch: {tis the axial distance from a point on one thread to comresponding point on next theta Lead: Ttis the distance the screw moves in one tum. 3, List some pes of commonly used thread forms. @ Square (i) SO metric Gi) ACME. 4. How is « bolt designated? ‘A bolt is designated by a eter followed by nominal diameter snd pitch in mm. BSW pa 5. State the advantages of coarse threads. @ Easier top cut Gi) Less seizure (Gil) Even stress distribution. 6, State the advantages of threaded joints. @ High clamping Gi) Small ehioning force requirement ‘Easy manufacturing Gv) Simple design. 7, What are differential and compound screws? ‘A difforential screw gives a motion equal to the difference of two pitehes. Compound serew gives a motion equal to the sum of two pitches. & What are the advantages of preloading? Hestops leakages. Gi) Teimproves fatigue strength. 9, What factors influence the amount of initial tension? @ External load (i) Material used Gi) Bott diameter Design of Bonded Joints 10, What is bot of uniform strength? A bolt of uniform strength has equal strongth a the thread and shank portion. 11, What are the ways to produce bolts of uniform strength? (@ Reducing shank diameter equal to root diameter. Gi) Drilling axial hot 3.125 12, What stresses act on screw fastenings? Initial stresses due to serewing up (i) Stesses due to extemal forces (ii) Combined stresses, 13, Define the term self-locking of power screws. [Anna Unis. Apy’04) If the friction angle (4) is greater than helix angle (x) of the power strew, the torque required to lower the load will be postive, indicating that an effort is applied to lower the load. This type is screw is known as self-locking sotew. The efficiency of the selflocking sorew isles than 50%, 14. Define welding. Welding can be defined as a process of joining two similar or dissimilar metals with or ‘without application of pressure along with or without addition of filler material | 1S. Why are welded joints preferred over riveted joins? ‘JAnna Unis. Nov'03] Material is saved in welding joints and hence the machine element will be light if ‘wold joints aro used instead of rivetd joints. Leak proof joints can be easity obtained by ‘welded joints compared riveted joints, 16. How is welding classified? (@) Forge welding (i)Btectic resistance welding and (Gil) Pusion welding, [Anna Unis. Apr'O5] 7, How is forged welding performed? ‘The parts to be welded are heated (o reach the plastic stage and the joint is prepared by applying impact force > 18. State something about elecric resistance welding. ‘he parts are pressured together and an cletrie curent is passed through thera So, the ‘etal is heated tothe fusion temperature3.126 Design ofMachine Elements. Design of Bonded Joints sur 19, State the main principle of fusion welding. 2S, Define Teejoint and commer joint “The «wo pioees to be joined are hested to the fusion teperamre by an oxy-acctylene Tioint fame or by an electric arc and then joined together by an additional filler material from a ‘The two plates aro arranged in *T” shape, which means the plates are located at right welding rod angles to each other. Corner weld 20, What are the general applications of welding? reece eee (Weng can be wed a a substi frarveted int ‘Twoplaes are ranged sight anges ach hatte a ng Gi) Welding can be used 98 a fabrication medium to join parts permanently and to 26 Define edge joint, form built-up pars For patos of thioknet le than Gram, the ends of the overlapping plates can be dsccly welded at the edges called edge weld Gil) Welding can be used to substitute casting and forging manufacturing methods. 21, What are the advantages of welding? (Welded joints are lighter in weight and have higher joining efficiency. (i) Welded joints are lesk proof and economical from the point of view of cost of material and labours. Git) The design of welded assemblies can be easily and economically modified to meet the changing product requirement. (Gv) The production time is less for welded assemblies. 22 State the limitations of welding. () _Ithas poor vibration damping characteristics. (ii) Welding results in a thermal distortion of the parts, thereby including residual stresses. Therefore, it nec stress relicving heat treatment Git) (iiyThe quality and strength of welded joints also depend pon the skill of the labours 23, What are the types of welded joints? ( Butt joint Gi-Lap joi iT joint (Go) Comer joint. (Edge joint: 24, Define butt and lap joint. But joint ‘The join is made by welding the ends or edges of two plates. Lap joint: “The two plates are overlapping each other for a certain distance. Then welded, Suck ‘welding is called filler weld. 217, State the weld symbols for double U-joint and single V-oint romans FP a sav.ns Fig. 3.78 28 State the types of force involved while designing. Tension and compressive forces 20, When will de edge preparation need? IF the two plates to be welded have more than Gam thickness, ths edge prparation shouldbe carried out. ee 40, Write down the formula for tensile strength ofa double V-groove but joint P=t+h) oo Where, P- tensile stress ny Bey weld sizes, 1 = lengh of weld = Allowable working ses. i, What are the ov types of fle weld? @, Longitudinal pata! it weld i) Transverse filet weld 432, Write dwn the formula for strength of fle and double fille For single fille, Pe Ax 0,707 hit For double filet, P=2Ac= 1.414 ht Where, f= weld sie length ofthe wad - Tensile tess3.128 Design of Machine Blements 43. Write down the formula forthe strength of single transverse fillet weld. P~Ao=0.07Alo Where, o Compressive stress, 34, Differentiate with a neat sketch the filet welds subjected to parallel loading and transverse [Anna Unis. Apr'04) 2] eee Flot wold subjected fo lwansverse loading loading, et wold subjected to ‘paral loading Fig. 3.79 35. Write down the formula for the strength of the combination of single traverse and filet welds Po Poamere * Pputet 0.707 h lea +2 x 0.707 x b be JOT hho LALA be 0.07 hho hs) 36, When will the weld deposit be weaker? ‘When the components are made of high earbon stel or alloy steel, the weld becomes ‘weaker. 37, Define eccentrically loaded welded joints. ‘The external loaded where applied may not pass through the geometric centre in structural joints called as eccentricaly Ioaded joints. 538, What are the two types of stresses are induced in eccentric loading of load joint? 4, Digest hose srs, ii, Bending or torsional shear stress 39, State the two types of eccentric welded connections. (Welded connoctions subjected to moment ina plane of the weld Gi) Welded connections subjected to moment in a plane normal to the plane of the weld Design of Bonded Jotnte 3.129 40. Write down the formula for maximum shear stress according to maximum sess theory. tant Ser 441, What isthe stress concentration factor? Where does it oceur? Due to abrupt change in cross section, some stress concentration will be formed, It ecurs a toe and heel pints. 2. What are the significances of welding specification? (To convey the designers idea to the welding operator by placing it t0 a suitable place ofthe drawing. 3) To specify the type of weld 43, What are the main indications of complete weld symbol? © Abbasic syabol is to specify the type of weld. (ii) An arrow and a reference lin to indicate the location ofthe weld, Gi) Supplementary symbols to indicate spocial inetrctions. (iv) Dimensions ofthe wold in exose section end lent, 3.6. REVIEW QUESTIONS What are the various types of screwed fasteners used in machine construction? Compare square thread with trapezoidal tread. List out the application areas of square, buterss and trapezoidal threads, Draw the bolt-deformation diagram and explain State how a bolt of uniform sttength is produced, ‘Whats a self-locking serew? Define, Welding and what are the main types of welding? ‘What ere the important general applications, advantages and limitations of welding? Explain the different types welded jie with et shetohes, 10, Write down the design procedure for longitudinal and transverse filet weld 11. Write down the design procedure for eoventrcally loaded welded joins 12, Write short notes on stress concentration factor. 13, Deseribe welding specification with ite elements and sketches. 3.7. PROBLEMS FOR PRACTICE L.A bolted joint is used to connect two components, The combined stiffness of the two ‘components is twice the bolt stiftess Initial tightening load is SEN. The extemal force of | LOK creates further tension in the bolt. The bolt is made of plain carbon steel 30C8 for ‘which yield strength in tension is 400N/num?. Using a factor of safety of 3 and assuming coarse threads, seloct a suitable bolt size, (Ans: M12)