Akademia Gorniczo-Hutnicza im.
Stanistawa Staszica w Krakowie
Wydziat Inzynierii Mechanicznej i Robotyki, Katedra Projektowania i Eksploatacji Maszyn
Didactic material for Fundamentals of Machine Design 1 design classes
WELDED JOINTS - Task 2
Check the load-bearing capacity of the connection between the I-beam IPE 240 and the column IPE 300
as shown in the figure below, made with fillet welds:
Data: I-beam material: $235 (St3S), for which: fg = 215 MPa
Loads: V = 120kN M =59kNm
Joint dimensions are given in the figure. For the reasons not discussed in the task. The welds of upper
flange are shorter, than the welds of lower flange: bet < bec.
Geometric characteristics of IPE 240:
A = 3912 mm?
br = 120 mm (flange width)
tp = 9.8mm (flange thickness)
ty = 6.2 mm (web thickness)
h=240mm Didactic material: PKM1 and FMD1, AGH, WIMIR, KPEM.
For design classes led by Department of Machine Design and
Maintenance (KPEM), WIMiR, AGH, 2025.
Opracowanie: A. Drzewosz, zmiany K. Michalczyk, 2025
Akademia Gorniczo-Hutnicza im. Stanistawa Staszica w Krakowie
Wydziat Inzynierii Mechanicznej i Robotyki, Katedra Projektowania i Eksploatacji Maszyn
Weld dimensions:
a, = 4mm (web weld throat thickness)
a2 = 7mm (flange weld throat thickness)
bet = 90 mm (length of external weld of upper flange)
bec = 120 mm (length of external weld of lower flange)
hy = 190 mm (length of web welds)
lg =42mm
lig = 27mm
Because welds of upper and lower flange are not equal, the position of neutral axis of welds has to be
detemined. The computational area of all welds:
As = 2+ hy + a1 + (Det + 2+ Ig) + a2 + (Dec + 2+ la) * a2
=2-190mm-4mm
+ (90mm + 2: 27 mm): 7mm + (120mm + 2-42mm)-7mm
= 3956mm?
Calculation of the static moment of the weld cross-sectional area with respect to the neutral axis of the I-
beam section (the vertical axis is assumed to be directed downwards):
h a h a2 h
Sy = Dee n° (-5-F) +2 Iyean: (“54 +2) +2 lace: (5- 7 -Z)
a2
+ dee aa (5+ Z)
h | a
240mm 7mm
= 90mm + 7mm -(-—S"" =~") 4. 2.27mm+7mm
240 mm 7mm 240 mm 7mm
(+
2,
9.8mm +S")
2
42-42 mm + 7mm (=2 — 9.8mm - =)
2
240mm 7mm
+ 120 mm +7 mm -(——"" 4. = 48342 mm?
The distance between the neutral axis of the welds cross-sectional area and the neutral axis of |-beam
cross-sectional area:
Sy 48342 mm?
= = 12.22
A, 3956mm2 nis
e=—=
Determination of the second moment of area of welds:
Didactic material: PKM1 and FMD1, AGH, WIMIR, KPEM.
For design classes led by Department of Machine Design and
Maintenance (KPEM), WIMiR, AGH, 2025.
Opracowanie: A. Drzewosz, zmiany K. Michalczyk, 2025
Akademia Gorniczo-Hutnicza im. Stanistawa Staszica w Krakowie
Wydziat Inzynierii Mechanicznej i Robotyki, Katedra Projektowania i Eksploatacji Maszyn
Dee * 3 ha r lg * a2? h a p
ly = 12
+ dee a2: (5+
2
Z-e) +2.(4 12 £ +lata-(F-4-F-e)
2 2 2
+2
( om + hy ay €8) 42: (28 tlg-aa-(F+ Ft —e) +g thee a2
y+ hy* Ig + 23 ch | a ) Pe
* a2
t
2
120mm: (7 mm)? 240mm 7mm
= 12
+ 120 mm + 7mm -(——""
2
4. 2
12.22 mm) +2
42 mm: (7 mm)? 240 mm 7mm Q
:| +42mm-7mm:(—""— 9.8mm —- — 12.22mm) +2
4mm - (190 mm)?
: —Tn + 190mm -4mm- (12.22 mm)? } + 2
27 mm - (7 mm)? -240mm 7mm P
°|— + 27mm: 7m: ("+ + 98mm- 12.22 mm)
12 2 2
90 mm- (7 mm)? -240mm 7mm :
fer +90mm:7mm-: — -— > 1222 mm) = 37410490 mm*
1, = 37410490 mm*
The cross-sectional area of welds connecting the web of IPE240 with the flange of IPE300:
Asw = 2+
a, + hy = 2-4mm- 190mm = 1520 mm?
CALCULATION OF BENDING STRESSES AT THE LOCATION FURTHEST FROM THE NEUTRAL AXIS, I.E. IN THE UPPER FLANGE
(INDEXxEs “1”)
Maximum distance from the neutral axis of the weld cross-section:
h a, 240mm 7mm
V1 =5+ > He vy «Ve 12.22
mm = 135.72 mm
Naprezenia normalne od zginania:
Didactic material: PKM1 and FMD1, AGH, WIMIR, KPEM.
M- M 59kNm : 135.72 mm For design classes led by Department of Machine Design and
O71 = ys
= 37410490 mm*
= 214.04MPa - a
Maintenance (KPEM), WIMiR, AGH, 2025.
.
Since the shear stresses from the transverse force in the |-beam flanges are much smaller than those in
the web welds, only the welds parallel to the shear force vector are assumed to carry this load in the
calculation of such connections. For the sake of simplicity, their value is calculated as average, i.e.
quotient of shear force and the cross-sectional area of vertical welds.
Calculations of normal component of stress:
Opracowanie: A. Drzewosz, zmiany K. Michalczyk, 2025
Akademia Gorniczo-Hutnicza im. Stanistawa Staszica w Krakowie
Wydziat Inzynierii Mechanicznej i Robotyki, Katedra Projektowania i Eksploatacji Maszyn
_ 04 _ 214.04MPa
O1=3=—pZ = 151.35 MPa
Selection of k coefficient value acc. To PN-B-03200:1990 standard:
Kk = 0.7 (k coefficient has such value acc. to the mentioned standard for steel with Re < 255 MPa)
Verification of the strength condition for reduced stresses according to the following formula:
Crea = K* Vo.” oe 367 al Ty?) = fa
O71 214.04
Oredi = KO, = K*—==0.7- MPa = 105.95 MPa
v2 v2
Creat = 105.195 MPa < fy = 215 MPa
Verification of the strength condition for normal stresses: 0, < fq:
04, = 151.35 MPa < fg = 215 MPa
Both conditions are fulfilled.
STRESS CALCULTAIONS IN WEB WELDS — THE WELD IS SHEARED AND BENDED (INDEXES “2”)
hy 190 mm
y2= zz +e= =z +t 12.22 mm = 107.22 mm
_M-y2 _ 59kNm- 107.22 mm _ 1¥o.1 he
2-7, 37410490? KRY
Gz _ 169-1MPa sy coup
Ce — i : a
“V2 v2
T, = 0, = 119.57 MPa
V 120 kN
T =7—-=Fs20mm2 78.95 MPa Didactic material: PKM1 and FMD1, AGH, WIMIR, KPEM.
sw sl For design classes led by Department of Machine Design and
nm = Oe Maintenance (KPEM), WIMiR, AGH, 2025.
(
Verification of the strength condition for reduced stresses
Gred2 = K° fou? +3 (t,2 + 12) = 0.7- J (119.57 MPa)? + 3 - ((119.57 MPa)2 + (78.95 MPa)2)
= 192.83 MPa
Crea2 = 192.83 MPa < fy = 215 MPa
Opracowanie: A. Drzewosz, zmiany K. Michalczyk, 2025
Akademia Gérniczo-Hutnicza im. Stanistawa Staszica w Krakowie
Wydziat Inzynierii Mechanicznej i Robotyki, Katedra Projektowania i Eksploatacji Maszyn
Verification of the strength condition for normal stresses: a, < fq:
0, = 119.57 MPa < fy = 215 MPa
Both conditions are fulfilled.
Conclusion:
The welded joint will withstand the given loads.
Didactic material: PKM1 and FMD1, AGH, WIMIR, KPEM.
For design classes led by Department of Machine Design and
Maintenance (KPEM), WIMiR, AGH, 2025.
Opracowanie: A. Drzewosz, zmiany K. Michalczyk, 2025