Chapter 3

Design of Joints and Torque Transmitting Elements

prepared by Abebe Z.
 3-1 Strength calculations and dimensioning of bolted joint

• In the specification standards for bolts,

▪ The strength is specified by stating SAE or ASTM minimum quantities,
▪ The minimum proof strength, or minimum proof load, and the minimum tensile
strength.
• The proof load is the maximum load (force) that a bolt can withstand without acquiring a
permanent set.
• The proof strength is the quotient of the proof load and the tensile-stress area.
• The proof strength thus corresponds roughly to the proportional limit and corresponds to
0.0001-in permanent set in the fastener (first measurable deviation from elastic behavior).
• Bolts in fatigue axial loading fail at the fillet under the head, at the thread runout, and at the
first thread engaged in the nut.
• If the bolt has a standard shoulder under the head, it has a value of K from 2.1 to 2.3, and
f

this shoulder fillet is protected from scratching or scoring by a washer.

• Nuts are graded so that they can be mated with their corresponding grade of bolt.
• The purpose of the nut is to have its threads deflect to distribute the load of the bolt more
evenly to the nut.
• The nut’s properties are controlled in order to accomplish this.
• The grade of the nut should be the grade of the bolt.
➢ The thread length for bolts and cap screws is
2𝑑 + 6 𝐿 ≤ 125
𝐿 𝑇 = 2𝑑 + 12 125 < 𝐿 ≤ 200
2𝑑 + 25 𝐿 > 200
where L is the bolt length.

• The thread length for structural bolts is slightly shorter than given above
3.1.1 Tension Joints—The External Load
▪ Let us consider a bolted connection subjected to an external tensile load P, as shown in figure.
▪ The clamping force, which we will call the preload 𝐹𝑖 , has been correctly applied by tightening
the nut before P is applied.
▪ The nomenclature used is:
𝐹𝑖 = preload
𝑃𝑡𝑜𝑡𝑎𝑙 = Total external tensile load applied to the join
P = external tensile load per bolt
Pb = portion of P taken by bolt
Pm = portion of P taken by members
Fb = Pb + Fi = resultant bolt load
Fm = Pm - Fi = resultant load on members
C = fraction of external load P carried by bolt
1 - C = fraction of external load P carried by members
N = Number of bolts in the joint
• If N bolts equally share the total external load, then
P = 𝑃𝑡𝑜𝑡𝑎𝑙 /N
• The load P is tension, and it causes the connection to stretch, or elongate, through some
distance δ.
• We can relate this elongation to the stiffnesses by recalling that k is the force divided by the
deflection. Thus
Pb Pm
δ= and δ=
Kb K𝑚
K𝑚
Or Pm = Pb
K𝑏
Kb P
Since P = Pb + Pm , we have Pb = = CP and Pm = P - Pb = (1 - C)P
Km + Kb
Kb
where C =
Km + Kb
is called the stiffness constant of the joint.
 The resultant bolt load is
𝐹𝑏 = Pb + 𝐹𝑖 = CP + 𝐹𝑖 𝐹𝑚 < 0 (Eq. 3 - 1)
and the resultant load on the connected members is
𝐹𝑚 = 𝑃𝑚 - 𝐹𝑖 = (1 - C)P - 𝐹𝑖 𝐹𝑚 < 0 (Eq. 3 - 2)
Of course, these results are valid only as long as some clamping load remains in the
members;
• Table 3 -1 is included to provide some information on the relative values of the
stiffnesses encountered.
▪ The grip contains only two members, both of steel, and no washers.

Stiffnesses, MN/m Table 3–1

Bolt Grip, in Kb K𝑚 C 1-C Computation of Bolt and Member
Stiffnesses.
2 450 2222.36 0.168 0.832 Steel members clamped
3 313.5 1984.19 0.136 0.864 using a 1/2 in-13 NC
Kb
steel bolt. C =
4 239.92 1861.59 0.114 0.886 Km + Kb
• The ratios C and 1 − C are the coefficients of P in Eqs. (3 - 1) and (3 - 2) respectively.
• They describe the proportion of the external load taken by the bolt and by the members,
respectively.
 3.1.2 Relating Bolt Torque to Bolt Tension

• If the overall length of the bolt can actually be measured with a micrometer when it is assembled,
the bolt elongation due to the preload Fi can be computed using the formula δ = 𝐹𝑖 l/(AE).
• Then the nut is simply tightened until the bolt elongates through the distance δ.
• This ensures that the desired preload has been attained.
• In such cases the wrench torque required to develop the specified preload must be estimated.
• Then torque wrenching, pneumatic-impact wrenching, or the turn-of-the-nut method may be used.
• The torque wrench has a built-in dial that indicates the proper torque.
• With impact wrenching, the air pressure is adjusted so that the wrench stalls when the proper torque
is obtained, or in some wrenches, the air automatically shuts off at the desired torque.
• The turn-of-the-nut method requires that we first define the meaning of snug-tight.
• The snug-tight condition is the tightness attained by a few impacts of an impact wrench, or the full
effort of a person using an ordinary wrench.
• When the snug-tight condition is attained, all additional turning develops useful tension in the bolt.
• The turn-of-the-nut method requires that you compute the fractional number of turns necessary to
develop the required preload from the snug-tight condition
• For example, for heavy hexagonal structural bolts, the turn-of-the-nut specification states that the nut
should be turned a minimum of 180𝑜 from the snug-tight condition under optimum conditions.
• Note that this is also about the correct rotation for the wheel nuts of a passenger car.
• Although the coefficients of friction may vary widely, we can obtain a good estimate of the torque
required to produce a given preload by
Fi dm 1+πfdm Secα Fi fc dc
T= +
2 πdm −flSecα 2
where 𝑑𝑚 is the average of the major and minor diameters. Since tan λ = l/π 𝑑𝑚 , we divide the
numerator and denominator of the first term by π𝑑𝑚 and get

Fi dm tanλ + f Secα Fi fc dc
T= +
2 1−f tanλSecα 2
• The diameter of the washer face of a hexagonal nut is the same as the width across flats
1
and equal to 1 times the nominal size.
2
• Therefore the mean collar diameter is 𝑑𝑚 = (d + 1.5d)/2 = 1.25d.
• Equation (b) can now be arranged to give
dm tanλ + f Secα
T= + 0.625fc Fi 𝑑
2𝑑 1−f tanλSecα
• We now define a torque coefficient K as the term in brackets, and so
dm tanλ + f Secα
K= + 0.625fc
2𝑑 1−f tanλSecα
• Equation (c) can now be written
T = K 𝐹𝑖 d
• The coefficient of friction depends upon the surface smoothness, accuracy, and degree
of lubrication.
• On the average, both f and f𝑐 are about 0.15.
• The interesting fact about Eq. (8–26) is that K = 0.20 for f = f𝑐 = 0.15 no matter what
size bolts are employed and no matter whether the threads are coarse or fine.
3.1.3 Statically Loaded Tension Joint with Preload

• Equations (3 - 1) and (3 - 2) represent the forces in a bolted joint with preload.

• The tensile stress in the bolt can be found as;
𝐹𝑏 𝐶𝑃+𝐹𝑖
σ𝑏 = = (a)
𝐴𝑡 𝐴𝑡
• Thus, the yielding factor of safety guarding against the static stress exceeding the proof
strength is
𝑆𝑝 𝑆𝑝
𝑛𝑝 = = (b)
σ𝑏 (𝐶𝑃+𝐹𝑖 )/𝐴𝑡
𝑆𝑝 𝐴𝑡
Or 𝑛𝑝 = (3-3)
𝐶𝑃+𝐹𝑖
• Another indicator of yielding that is sometimes used is a load factor, which is applied only to the
load P as a guard against overloading.
• Applying such a load factor to the load P in Eq. (a), and equating it to the proof strength gives
𝐶𝑛𝑙 𝑃+𝐹𝑖
𝑆𝑝 = (c)
𝐴𝑡
• Solving for the load factor gives
𝑆𝑝 𝐴𝑡 −𝐹𝑖
𝑛𝑙 = (3-4)
𝐶𝑃
• It is also essential for a safe joint that the external load be smaller than that needed to cause the
joint to separate.
• If separation does occur, then the entire external load will be imposed on the bolt. Let P0 be the
value of the external load that would cause joint separation.
• At separation, 𝐹𝑚 = 0 in Eq. (3 - 2), and so
(1 - C) P0 - 𝐹𝑖 = 0 (d)
𝑃𝑜
• Let the factor of safety against joint separation be 𝑛𝑜 = (e)
𝑃
Substituting 𝑃𝑜 = 𝑛𝑜 P in Eq(d) we find
𝐹𝑖
𝑛𝑜 = (3-5)
𝑃(1−𝐶)

as a load factor guarding against joint separation

• Figure 3–2 is the stress-strain diagram of a good-quality bolt
material.
• Notice that there is no clearly defined yield point and that the
diagram progresses smoothly up to fracture, which
corresponds to the tensile strength.
• This means that no matter how much preload is given the
bolt, it will retain its load-carrying capacity.
• This is what keeps the bolt tight and determines the joint
strength.
• The pretension is the “muscle” of the joint, and its magnitude
is determined by the bolt strength.
• If the full bolt strength is not used in developing the
pretension, then money is wasted and the joint is weaker.
• Some of the bolt torque used in tightening produces torsion, Figure 3–2
Typical stress-strain diagram for bolt
which increases the principal tensile stress. materials showing proof strength Sp, yield
strength Sy, and ultimate tensile strength
Sut
• However, this torsion is held only by the friction of the bolt head and nut; in time it relaxes and
lowers the bolt tension slightly.
• Thus, as a rule, a bolt will either fracture during tightening, or not at all.
• Based on different guidelines, it is recommended for both static and fatigue loading that the
following be used for preload on bolts:
0.75𝐹𝑝 𝑓𝑜𝑟 𝑛𝑜𝑛 𝑝𝑒𝑟𝑚𝑎𝑛𝑒𝑛𝑡 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑜𝑛𝑠, 𝑟𝑒𝑢𝑠𝑒𝑑 𝑓𝑎𝑠𝑡𝑒𝑛𝑒𝑟𝑠
𝐹𝑖 = ൝ (3-6)
0.90𝐹𝑝 𝑓𝑜𝑟 𝑝𝑒𝑟𝑚𝑎𝑛𝑒𝑛𝑡 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑜𝑛𝑠
𝐹𝑖 = for permanent connections
where 𝐹𝑝 is the proof load, obtained from the equation

𝐹𝑝 = 𝐴𝑡 𝑆𝑝 (3-7)
• Here 𝑆𝑝 is the proof strength obtained from standard table.
• For other materials, an approximate value is 𝑆𝑝 = 0.85 𝑆𝑦 .
• Be very careful not to use a soft material in a threaded fastener. For high-strength steel bolts used as
structural steel connectors, if advanced tightening methods are used, tighten to yield.
 3.1.4 Fatigue Loading of Tension Joints
• Tension-loaded bolted joints subjected to fatigue action can be analyzed directly by the
methods of Chap. 2.
• Table 3–2 lists average fatigue stress-concentration factors for the fillet under the bolt
head and also at the beginning of the threads on the bolt
shank.
• These are already corrected for notch sensitivity and for surface finish.

Table 3–2 Fatigue Stress Concentration Factors K f for

Threaded Elements
• Fully corrected (including K f ) axial endurance strength is reported in Table 3–3.

• For a general case with a

constant preload, and an
external load on a per bolt
basis fluctuating between
Pmin and Pm𝑎𝑥 , a bolt will
experience fluctuating forces
such that
Fbmin = C Pm𝑖𝑛 + Fi (a)
Fbm𝑎𝑥 = C Pm𝑎𝑥 + Fi (b)

Table 3–3 Fully Corrected Endurance Strengths for Bolts and Screws
with Rolled Threads
• The alternating stress experienced by a bolt is
(𝐹𝑏𝑚𝑎𝑥 −Fbm𝑖𝑛) /2 (𝐶𝑃𝑚𝑎𝑥 +𝐹𝑖 )−(𝐶𝑃𝑚𝑖𝑛 +𝐹𝑖 )
σ𝑎 = =
𝐴𝑡 2𝐴𝑡
𝐶(𝑃𝑚𝑎𝑥 −𝑃𝑚𝑖𝑛 )
σ𝑎 = (3-8)
2𝐴𝑡

• The midrange stress experienced by a bolt is

(𝐹𝑏𝑚𝑎𝑥 +Fbm𝑖𝑛) /2 (𝐶𝑃𝑚𝑎𝑥 +𝐹𝑖 )+(𝐶𝑃𝑚𝑖𝑛 +𝐹𝑖 )
σ𝑚 = =
𝐴𝑡 2𝐴𝑡
𝐶(𝑃𝑚𝑎𝑥 +𝑃𝑚𝑖𝑛 ) 𝐹𝑖
σ𝑚 = + (3-9)
2𝐴𝑡 𝐴𝑡
• The fatigue factor of safety is given by
𝑆𝑒 (𝑆𝑢𝑡 −σ𝑖 )
𝑛𝑓 = (3-10)
𝑆𝑢𝑡 σ𝑎 +𝑆𝑒 (σ𝑚 −σ𝑖 )
 3-2 Strength calculations and dimensioning of riveted joints

• A Rivet is a short cylindrical rod having a head and a tapered tail.

• The main body of the rivet is called shank and lower portion of the shank
is known as tail (see figure).
•

Figure 3–2 Rivets and its parts

3-2-1 Types of rivet joints

• The two types of riveted joints, depending upon the way in which the plates are connected
1. Lap joints 2. Butt joints

1. Lap joints
• A lap joint is that in which one plate overlaps
the other and the two plates are then riveted
together.
• Rivets are inserted on the overlapping portion.
• Single or multiple rows of rivets are used to
give strength to the joint.
• Depending upon the number of rows the riveted
joints may be classified as single riveted lap
Figure 3–3 Lap joint
joint, double or triple riveted lap joint etc.
2. Butt joints
• A butt joint is that in which the main plates are kept in alignment butting (i.e. touching)
each other and a cover plate (i.e. strap) is placed either on one side or on both sides of
the main plates.
• The cover plate is then riveted together with the main plates.
• Depending upon the number of cover plates butt joints are of the following two types :
1. Single strap butt joint, and 2. Double strap butt joint.

Figure 3–4 Butt joint

• In addition to the above, following are the types of riveted joints depending upon the
number of rows of the rivets.
1. Single riveted joint, and 2. Double riveted joint.
• A single riveted joint is that in which there is a single row of rivets in a lap joint as shown in Fig.
9.6 (a) and there is a single row of rivets on each side in a butt joint as shown in Fig. 9.8.
• A double riveted joint is that in which there are two rows of rivets in a lap joint as shown in Fig.
9.6 (b) and (c) and there are two rows of rivets on each side in a butt joint as shown in Fig. 9.9

Fig. 3-5 Single and

double riveted lap
joints.

(b) Double riveted lap (c) Double riveted lap

(a) Single riveted lap joint
joint (Chain riveting joint (Zig-zag riveting).
3-2-2 Important Terms Used in Riveted Joints

• The following terms in connection with the riveted joints are important from the subject
point of view :
1. Pitch. It is the distance from the centre of one rivet to the centre of the next rivet measured
parallel to the seam as shown in Fig. 3-5 . It is usually denoted by p.
2. Back pitch. It is the perpendicular distance between the centre lines of the successive rows as
shown in Fig. 3-5 . It is usually denoted by pb.
3. Diagonal pitch. It is the distance between the centres of the rivets in adjacent rows of zig-zag
riveted joint as shown in Fig. 3-5 . It is usually denoted by pd.
4. Margin or marginal pitch. It is the distance between the centre of rivet hole to the nearest edge
of the plate as shown in Fig. 3-5 . It is usually denoted by m.
 3-2-3 Failures of a Riveted Joint

A riveted joint may fail in the following ways:

1. Tearing of the plate at an edge. A joint may fail due
to tearing of the plate at an edge as shown in Fig. 3-6.
This can be avoided by keeping the margin, m = 1.5d,
where d is the diameter of the rivet hole.

Fig. 3-6. Tearing of the plate at an edge.

2. Tearing of the plate across a row of rivets. Due to
the tensile stresses in the main plates, the main plate or
cover plates may tear off across a row of rivets as
shown in Fig. 3-7.
• In such cases, we consider only one pitch length of
the plate, since every rivet is responsible for that
much length of the plate only.
• The resistance offered by the plate against tearing is
known as tearing resistance or tearing strength or
tearing value of the plate. Fig. 3-7. Tearing of the plate
across the rows of rivets.
Let p = Pitch of the rivets,
d = Diameter of the rivet hole,
t = Thickness of the plate, and
σt = Permissible tensile stress for the plate material.
We know that tearing area per pitch length,
𝐴t = ( p – d ) t
Therefore, tearing resistance or pull required to tear off the plate per pitch length,
𝑃t = 𝐴t σt = (p – d)t. σt
When the tearing resistance (𝑃t ) is greater than the applied load (P) per pitch length, then
this type of failure will not occur.
3. Shearing of the rivets. The plates which are connected by the rivets exert tensile stress on
the rivets, and if the rivets are unable to resist the stress, they are sheared off as shown in
Fig. 3-8.
It may be noted that the rivets are in single shear in a lap joint and in a single cover butt
joint, as shown in Fig. 3-8. But the rivets are in double shear in a double cover butt joint as
shown in Fig. 3-9.

Fig. 3-9 Shearing off a rivet

in double cover butt joint.
Fig. 3-8. Shearing of rivets.
• The resistance offered by a rivet to be sheared off is known as shearing resistance or
shearing strength or shearing value of the rivet.
Let d = Diameter of the rivet hole,
τ = Safe permissible shear stress for the rivet material, and
n = Number of rivets per pitch length.
We know that shearing area,
π
𝐴𝑠 = 𝑑 2 ...(In single shear)
4
π
𝐴𝑠 = 2 x 𝑑 2 ...(Theoretically, in double shear)
4 π 2
𝐴𝑠 = 1.875 x 𝑑 ...(In double shear, according to Indian Boiler Regulations)
4
Therefore, Shearing resistance or pull required to shear off the rivet per pitch length,
π
𝑃𝑠 = n x 𝑑 2 x τ ...(In single shear)
4
π 2
𝑃𝑠 = n x 2 x 𝑑 x τ ...(Theoretically, in double shear)
4
 π 2
𝑃𝑠 = n x 1.875 x 𝑑 x τ ...(In double shear, according to Indian Boiler Regulations)
4
▪ When the shearing resistance (𝑃𝑠 ) is greater than the applied load (P) per pitch
length, then this type of failure will occur.
4. Crushing of the plate or rivets. Sometimes, the
rivets do not actually shear off under the tensile
stress, but are crushed as shown in Fig. 3-10.
• Due to this, the rivet hole becomes of an oval
shape and hence the joint becomes loose.
• The failure of rivets in such a manner is also
known as bearing failure.
• The area which resists this action is the projected
area of the hole or rivet on diametral plane.

Fig. 3-10. Crushing of a rivet

Let d = Diameter of the rivet hole,
t = Thickness of the plate,
σ𝑐 = Safe permissible crushing stress for the rivet or plate material, and
n = Number of rivets per pitch length under crushing
We know that crushing area per rivet (i.e. projected area per rivet),
𝐴𝑐 = d x t
Therefore total crushing area = n.d.t
▪ Crushing resistance or pull required to crush the rivet per pitch length,
𝑃𝑐 = n.d.t.σ𝑐
▪ When the crushing resistance (𝑃𝑐 ) is greater than the applied load (P) per pitch length,
then this type of failure will occur.
Note : The number of rivets under shear shall be equal to the number of rivets under
crushing
3-2-4 Strength of a Riveted Joint

• The strength of a joint may be defined as the maximum force, which it can transmit,
without causing it to fail.
• We have seen in that 𝑃𝑡 , 𝑃𝑠 and 𝑃𝑐 are the pulls required to tear off the plate, shearing off
the rivet and crushing off the rivet.
• A little consideration will show that if we go on increasing the pull on a riveted joint, it
will fail when the least of these three pulls is reached, because a higher value of the
other pulls will never reach since the joint has failed, either by tearing off the plate,
shearing off the rivet or crushing off the rivet.
• If the joint is continuous as in case of boilers, the strength is calculated per pitch length.
But if the joint is small, the strength is calculated for the whole length of the plate.
3-2-5 Efficiency of a Riveted Joint

• The efficiency of a riveted joint is defined as the ratio of the strength of riveted joint to
the strength of the un-riveted or solid plate.
• We have already discussed that strength of the riveted joint = Least of 𝑃𝑡 , 𝑃𝑠 and 𝑃𝑐
Strength of the un-riveted or solid plate per pitch length,
P = p × t × σ𝑡
Therefore, Efficiency of the riveted joint,

Least of 𝑃𝑡 , 𝑃𝑠 and 𝑃𝑐
η=
p × t × σ𝑡
where, p = Pitch of the rivets, t = Thickness of the plate, and
σ𝑡 = Permissible tensile stress of the plate material
3-3 Strength calculations and dimensioning of welded joints

• A welded joint is a permanent joint which is obtained by the

fusion of the edges of the two parts to be joined together,
with or without the application of pressure and a filler
material.
• The heat required for the fusion of the material may be
obtained by burning of gas (in case of gas welding) or by an
electric arc (in case of electric arc welding).
• Welding is extensively used in fabrication as an alternative
method for casting or forging and as a replacement for bolted
and riveted joints.
• It is also used as a repair medium e.g. to reunite metal at a
crack, to build up a small part that has broken off such as gear
tooth or to repair a worn surface such as a bearing surface.
3-3.1 Advantages and Disadvantages of Welded Joints over Riveted Joints
• Following are the advantages and disadvantages of welded joints over riveted joints.
Advantages
1. The welded structures are usually lighter than riveted structures due to the reason, that in
welding, gussets or other connecting components are not used.
2. The welded joints provide maximum efficiency (may be 100%) which is not possible in case
of riveted joints.
3. Alterations and additions can be easily made in the existing structures.
4. In welded connections, the tension members are not weakened as in the case of riveted joints.
5. A welded joint has a great strength often has the strength of the parent metal itself.
7. Sometimes, the members are of such a shape (i.e. circular steel pipes) that they afford
difficulty for riveting, but they can be easily welded.
8. The welding provides very rigid joints.
9. It is possible to weld any part of a structure at any point, but riveting requires enough
clearance.
10. The process of welding takes less time than the riveting.
Disadvantages
1. Since there is an uneven heating and cooling during fabrication, therefore the
members may get distorted or additional stresses may develop.
2. It requires a highly skilled labour and supervision.
3. Since no provision is kept for expansion and contraction in the frame, therefore there
is a possibility of cracks developing in it.
4. The inspection of welding work is more difficult than riveting work.
3-3.2 Types of Welded Joints

• Following two types of welded joints are important from the subject
point of view:
1. Lap joint or fillet joint, and 2. Butt joint.

(a) Single transverse (b) Double transverse (b) Parallel fillet

Fig. 3.11. Types of lap or fillet joints.
 (a) Lap Joint

• The lap joint or the fillet joint is obtained by overlapping the

plates and then welding the edges of the plates.
• The cross-section of the fillet is approximately triangular.
• They are most commonly used to joint two pieces with
differing thicknesses together.
• Welds can be made on one or both sides.
• The fillet joints may be
1. Single transverse fillet, 2. Double transverse fillet, and 3. Parallel fillet joints.
• The fillet joints are shown in Fig. 3.11.
• A single transverse fillet joint has the disadvantage that the edge of the plate which is not
welded can buckle or warp out of shape.
 (b) Butt Joint

• The butt joint is obtained by placing the plates edge

to edge as shown in Fig. 3.12.
• In butt welds, the plate edges do not require beveling
if the thickness of plate is less than 5 mm.
• On the other hand, if the plate thickness is 5 mm to
12.5 mm, the edges should be beveled to V or U-
groove on both sides.

(a) Single butt joint (b) Single v-butt joint (c) Single u-butt joint (d) double v-butt joint (d) double u-butt joint
Fig. 3.12 Types of butt joints
• The other type of welded joints are corner joint, edge joint and T-joint as shown in Fig. 3.13

(a) Corner joint (b) Edge joint. (c) T-joint.

Fig. 3.13. Other types of welded joints.

• The main considerations involved in the selection of weld type are:

1. The shape of the welded component required,
2. The thickness of the plates to be welded, and
3. The direction of the forces applied.
 3.3.3 Strength of Transverse Fillet Welded Joints

• The transverse fillet welds are designed for tensile strength.

• Let us consider a single and double transverse fillet welds as shown in Fig. 3.14 (a) and (b)
respectively

(a) single transverse fillet weld (b) double transverse fillet weld

Fig. 3.14. Transverse fillet welds.

▪ In order to determine the strength of the fillet joint, it is assumed that the section of
fillet is a right angled triangle ABC with hypotenuse AC making equal angles with
other two sides AB and BC.
• The enlarged view of the fillet is shown in Fig.
3.15.
• The length of each side is known as leg or size
of the weld and the perpendicular distance of
the hypotenuse from the intersection of legs
(i.e. BD) is known as throat thickness.
• The minimum area of the weld is obtained at
the throat BD, which is given by the product Fig. 3.15. Enlarged view of a fillet weld.
of the throat thickness and length of weld.
Let t = Throat thickness (BD),
From Fig. 3.15, we find that the throat thickness, s = Leg or size of weld,
t = s × sin 45° = 0.707 s = Thickness of plate, and
∴ Minimum area of the weld or throat area, l = Length of weld,
A = Throat thickness × Length of weld = t × l = 0.707 s × l
• If σ𝑡 is the allowable tensile stress for the weld metal, then the tensile strength of the
joint for single fillet weld,
P = Throat area × Allowable tensile stress = 0.707 s × l × σ𝑡
and tensile strength of the joint for double fillet weld,
P = 2 × 0.707 s × l × σ𝑡 = 1.414 s × l × σ𝑡
• Note: Since the weld is weaker than the plate due to slag and blow holes, therefore the
weld is given a reinforcement which may be taken as 10% of the plate thickness.
 3.3.4 Strength of Parallel Fillet Welded Joints

• The parallel fillet welded joints are designed for shear strength.
• Consider a double parallel fillet welded joint as shown in Fig. 3.14 (a).
• We have already discussed in the previous article, that the minimum
area of weld or the throat area,
A = 0.707 s × l (a) Double parallel fillet weld

* The minimum area of the weld is taken because the stress is maximum at the
minimum area
If τ is the allowable shear stress for the weld metal, then the shear
strength of the joint for single parallel fillet weld,
P = Throat area × Allowable shear stress = 0.707 s × l × τ
and shear strength of the joint for double parallel fillet weld, (b) Combination of transverse and
P = 2 × 0.707 × s × l × τ = 1.414 s × l × τ parallel fillet weld.

Fig. 3.14
• Notes: 1. If there is a combination of single transverse and double parallel fillet welds as
shown in Fig. 3.14 (b), then the strength of the joint is given by the sum of strengths of
single transverse and double parallel fillet welds.
Mathematically,
P = (0.707s × 𝒍𝟏 × σ𝒕 ) + (1.414 s × 𝒍𝟐 × τ)
where 𝒍𝟏 is normally the width of the plate.
2. In order to allow for starting and stopping of the bead, 12.5 mm should be added to
the length of each weld obtained by the above expression.
3. For reinforced fillet welds, the throat dimension may be taken as 0.85 t.
 3.3.5 Special Cases of Fillet Welded Joints

• The following cases of fillet welded joints are important from the subject point of view.
1. Circular fillet weld subjected to torsion. Consider a circular rod connected to a rigid
plate by a fillet weld as shown in Fig. 3.15
Let d = Diameter of rod, s = Size (or leg) of weld,
r = Radius of rod, t = Throat thickness,
T = Torque acting on the rod, J = Polar moment of inertia of the weld section
π t d3
J=
4
We know that shear stress for the material,
Tr T 𝑑/2 T 𝑑/2 2T T τ
τ= = = = from =
J J π t d3 /4 π t d2 J r

• This shear stress occurs in a horizontal plane along a leg of the fillet
weld. Fig. 3.15. Circular fillet weld
• The maximum shear occurs on the throat of weld which is inclined at 45° subjected to torsion
to the horizontal plane.
∴ thickness of throat,
t = s sin 45° = 0.707 s
and maximum shear stress,
2T 2.83T
τ𝑚𝑎𝑥 = =
π×0.707𝑠 ×d2 π𝑠d2
2. Circular fillet weld subjected to bending moment. Consider a circular rod connected
to a rigid plate by a fillet weld as shown in Fig. 3.16.
Let d = Diameter of rod, t = Throat thickness,
M = Bending moment acting on the rod, Z = Section modulus of the weld section
s = Size (or leg) of weld,
π t d2
Z=
4
• We know that the bending stress,
M M 4M
σ𝑏 = = =
Z π t d2 /4 π t d2
• This bending stress occurs in a horizontal plane along a leg of the
fillet weld.
• The maximum bending stress occurs on the throat of the weld which is
inclined at 45° to the horizontal plane.
∴ thickness of throat, t = s sin 45° = 0.707 s
and maximum bending stress,
Fig. 3.16. Circular fillet weld
4M 5.66M
σ𝑏(max) = = subjected to bending moment.
π 𝑥 0.707s 𝑥 d2 πsd2
3. Long fillet weld subjected to torsion. Consider a vertical plate attached to a horizontal
plate by two identical fillet welds as shown in Fig. 3.16.
Let T = Torque acting on the vertical plate,
l = Length of weld,
s = Size (or leg) of weld,
t = Throat thickness, and
t 𝑥 𝑙3 t 𝑥 𝑙3
J = Polar moment of inertia of the weld section = 2 x =
12 6
(because of both sides weld)
▪ It may be noted that the effect of the applied torque is to rotate the Fig. 3.16. Long fillet weld subjected
vertical plate about the Z-axis through its mid point. to torsion.
▪ This rotation is resisted by shearing stresses developed between two
fillet welds and the horizontal plate.
▪ It is assumed that these horizontal shearing stresses vary from zero at the Z-axis and maximum at
the ends of the plate.
▪ This variation of shearing stress is analogous to the variation of normal stress over the depth (l)
of a beam subjected to pure bending
 T 𝑥 𝑙/2 3T
∴ Shear stress, τ = =
t 𝑥 𝑙 3 /6 t 𝑥 𝑙2
The maximum shear stress occurs at the throat and is given by
3T 4.242T
τ𝑚𝑎𝑥 = =
0.707𝑠 𝑥 𝑙 2 s 𝑥 𝑙2
 3.3.6 Strength of Butt Joints

• The butt joints are designed for tension or compression.

• Consider a single V-butt joint as shown in Fig. 3.17 (a).
• In case of butt joint, the length of leg or size of weld is equal to
the throat thickness which is equal to thickness of plates.
(a) single V-butt joint
Therefore, tensile strength of the butt joint (single-V or square butt joint),
P = t × l × σ𝑡
where l = Length of weld which is equal to the width of plate.
and tensile strength for double-V butt joint as shown in Fig. 3.17 (b) is given by

P = (t1 + t2 ) l × σ𝑡
where t1 = Throat thickness at the top, and t2 = Throat thickness at the bottom.

• It may be noted that size of the weld should be greater than the thickness of
(b) double V-butt joint
the plate, but it may be less.
Fig. 3.17. Butt joints
• The following table shows recommended minimum size of the welds.

Table 3-4. Recommended minimum size of welds.

Thickness of plate (mm) 3–5 6–8 10 – 16 18 – 24 26 – 55 Over 58

Minimum size of weld (mm) 3 5 6 10 14 20

3.3.7 Stress Concentration Factor for Welded Joints

• The reinforcement provided to the weld produces stress concentration at the

junction of the weld and the parent metal. When the parts are subjected to fatigue
loading, the stress concentration factor as given in the following table should be
taken into account

Table 3-5. Stress concentration factor for welded joints.

Type of joint Stress concentration factor

1. Reinforced butt welds 1.2
2. Toe of transverse fillet welds 1.5
3. End of parallel fillet weld 2.7
4. T-butt joint with sharp corner 2

Note : For static loading and any type of joint, stress concentration factor is 1.0.
Workout problems

3 3
1. A in-16 UNF × in SAE grade 5 bolt is subjected to a load P of 60 KN in
4 4
a tension joint. The initial bolt tension is F𝑖 = 75 KN. The bolt and joint
stiffnesses are
K𝑏 = 6.50 and K𝑚 = 13.8 MN/m, respectively.
(a) Determine the preload and service load stresses in the bolt.
(b) Specify the torque necessary to develop the preload
Note: use Table 8–2 from Shigley's Mechanical Engineering Design book
2. A double riveted lap joint is made between 15 mm thick plates. The rivet
diameter and pitch are 25 mm and 75 mm respectively. If the ultimate
stresses are 400 MPa in tension, 320 MPa in shear and 640 MPa in crushing,
find the minimum force per pitch which will rupture
the joint.
If the above joint is subjected to a load such that the factor of safety is 4, find
out the actual stresses developed in the plates and the rivets.
3. Find the efficiency of the following riveted joints :
1. Single riveted lap joint of 6 mm plates with 20 mm diameter rivets having a pitch of 50 mm.
2. Double riveted lap joint of 6 mm plates with 20 mm diameter rivets having a pitch of 65 mm.
Assume
Permissible tensile stress in plate = 120 MPa
Permissible shearing stress in rivets = 90 MPa
Permissible crushing stress in rivets = 180 MPa
4. A plate 100 mm wide and 10 mm thick is to be welded to another plate by means of
double parallel fillets. The plates are subjected to a static load of 80 kN. Find the length
of weld if the permissible shear stress in the weld does not exceed 55 MPa.
5. A 50 mm diameter solid shaft is welded to a flat plate by 10 mm fillet
weld as shown in figure. Find the maximum torque that the welded joint
can sustain if the maximum shear stress intensity in the weld material is
not to exceed 80 MPa.
6. A plate 100 mm wide and 12.5 mm thick is to be welded to another
plate by means of parallel fillet welds. The plates are subjected to a load
of 50 kN. Find the length of the weld so that the maximum stress does
not exceed 56 MPa. Consider the joint first under static loading and then
under fatigue loading
7. A plate 1 m long, 60 mm thick is welded to another plate at right angles to
each other by 15 mm fillet weld, as shown in Fig. Find the maximum torque
that the welded joint can sustain if the permissible shear stress intensity in the
weld material is not to exceed 80 MPa.
8. A plate 75 mm wide and 12.5 mm thick is joined with another plate by a single
transverse weld and a double parallel fillet weld as shown in figure. The maximum
tensile and shear stresses are 70 MPa and 56 MPa respectively. Find the length of
each parallel fillet weld, if the joint is subjected to both static and fatigue loading.
 Assignment
1. In a mechanical component design why do we care what the stresses and strengths are?
Explain it in relation with factor of safety.
2. Explain the following terms in connection with design of machine members subjected to
variable loads:
(a) Endurance limit (b) Size factor
(c) Surface finish factor, and (d) Notch sensitivity
3. Write Soderberg's equation, explain what information do you obtain from Soderberg
diagram and state its application to different type of loadings.
4. Take any practical examples of bolt/screw/rivet joint/weld joint, elaborate all its design
parameters.
5. Show by neat sketches the various ways in which a riveted joint may fail.
6. What do you understand by the term welded joint? How it differs from riveted joint?