Welds in Shear, Bending, Torsion and Axial Loading

User Notes for

The Analysis & Design of Weld Groups
Subjected to Simultaneous Shear, Bending, Torsion and Axial Loading
WeldCalc
by
Dr Shaiq U.R. Khan
BEng (Civil), MEng, PhD, PE, CEng, FIStructE
November 2004

Introduction
WeldCalc analyses any configuration of multi-linear weld lengths in an X-Y plane. The
loads can be shear, moment, torsion and axial applied simultaneously.

WeldCalc calculates the induced stress at each node and identifies the node most
highly stressed. It also calculates the magnitude of load resisted by each length of weld
in the x, y and z direction.

A weld group can have up to 30 Nodes or 29 weld lengths. The line of weld lengths can
be continuous or discontinuous. Each continuous series of weld lengths is termed as a
Part and it is given a reference number starting from 1 onwards. A weld group can
have up to 15 parts connecting 30 nodes in any pattern.

Loading the Template on to your Computer

WeldCalc is supplied as an Excel Template, having .XLT as its filename extension.

You can use WeldCalc by opening its file directly or copying it into the Microsoft Office
folder for its Templates. Consult Microsoft Office documentation for the path to this
folder.
For example, if you are using Excel 2000, the path to this folder is:
C:\Windows\Application Data\Microsoft\Templates

To load and use the Template in Excel 2000, choose:

File, New and the select the file [Link]

When opening the WeldCalc file, Excel issues a routine Warning about running
Macros and prompts whether or not to load them.

Answer YES to Load and Enable Macros. WeldCalc incorporates VB Macros and to
allow your computer to use them is vital for its operation.

Codes of Practice
WeldCalc is a weld analysis program for International use. It is not dependent on the
use of any specific code of practice.

However, to illustrate the use of WeldCalc and to discuss various weld details for
design purposes ,reference has been to the British Standard Code of Practice BS 5950-
1: 2000 Part 1, Structural Use of Steelwork in Building1.

Using WeldCalc
In addition to Job Information in the heading part, describe Applied Loads, Design
Strength and details for each weld length. The applied loads can be factored or un-
factored depending upon the specified design strength of welds. The weld details
required are: part-number, coordinates x and y and throat thickness at each node.

File: WeldCalc20041115-2 Tab: Notes Page 1/8 Date Printed: 2022/2/18

 Welds in Shear, Bending, Torsion and Axial Loading

File: WeldCalc20041115-2 Tab: Notes Page 2/8 Date Printed: 2022/2/18

 Welds in Shear, Bending, Torsion and Axial Loading

WeldCalc also incorporates a data store facility. Information for up to 500 weld groups
is kept in the worksheet STORE. Clicking the "Store Existing Data" command button in
the top row, saves the current weld group data. Clicking the "Get Stored Data" button
retrieves the previously saved information.

In order to save or retrieve a weld group information, the Template uses a Datastore
Number. This number for 500 weld groups (in the range from 1001 to 1500) must be
specified to store or retrieve weld group data.

PLEASE NOTE that storing weld group data does not save the Excel File. To ensure
saving data to your hard disk, you must use Excel File, Save Pull Down Menu Option in
the usual Windows procedure.

Likewise, saving Excel file to hard disk does not store the existing screen data into the
worksheet "STORE". To do so, you must use "Store Existing Data" button before
saving the Excel file to hard disk.

Database of Weld Group Details and Applied Loading: Worksheet STORE

In each WeldCalc file, weld connection details and applied loads can be stored for 500
weld groups. Each weld group is referenced by a number in the range 1001 to 1500.
All information is kept in the worksheet STORE and is available to the user for use in
the design process.
A casual Excel user generally does not need to tweak or amend the STORE worksheet.
At the risk of upsetting this information, however, one can benefit by generating and
using this information by Copy, Paste-Special-Values and Fill-Down commands of
Excel.
It is strongly recommended that Cut Command of Excel is not used on this worksheet;
using this command affects the worksheet layout and can disrupt the working of
WeldCalc. Similarly the use of Paste command (as opposed to Paste-Special-Values
command) can override the helpful cell formats.
An experienced Excel User can employ various Excel features to tweak or manage this
information. For example, user reference, title, design strength values can be
generated via Copy, Paste-Special-Values and Fill Down features of the spreadsheet.

Auto Analysis of Weld Groups

Use this facility to analyse and or print all weld groups by a single click of “Auto
Analyse/Print” Button in the top right corner of the screen.
To use this facility, two columns coloured in yellow to the right of the “Store” worksheet
are provided. One column is headed “Analyse Y?” and the other as “Print ?”. The
“Auto Analyse/Print” Button is located at the top of these two columns in the Worksheet
“Store”.

Entering “Y” in these two columns, signifies that the respective weld group in a given
row need to be analysed and or printed. Leaving the cells blank signifies that
respective weld groups are not to be analysed or printed.

Auto Analysis facility is useful when all or a selected few weld groups are to be
analysed and or printed after updating the weld group details and loading in the STORE
worksheet.

File: WeldCalc20041115-2 Tab: Notes Page 3/8 Date Printed: 2022/2/18

 Welds in Shear, Bending, Torsion and Axial Loading

Design of Fillet Welds

The vector sum of the design stresses due to all forces and moments transmitted by
the weld should not exceed the design strength.

When using BS 5950 the design strength pw under factored loads is 0.220 kN/mm 2 for
S275 Grade, 0.250 kN/mm2 for Grade S355 and 0.280 kN/mm2 for Grade S460 (Table
37, Cl 6.8.5).

Throat Thickness
The size of the fillet is expressed by the length of the leg of the largest isosceles right
angle triangle that can be inscribed on the outline of the weld. The weld usually has
equal legs, but conditions may require the use of weld with unequal legs.

Thickness of the weld is measured by the perpendicular drawn from the intersection of
the legs on to the hypotenuse, as shown in the figure. This is called the throat
thickness or simply Throat of the fillet weld.

The strength of the fillet welds is related to the throat thickness and depends upon the
angle between the fusion faces. This relationship between the leg length s and the
throat thickness a for various angles between fusion faces is given as follows:

Weld size Fy, y

60o to 90o, a = 0.7 s My
s
91o to 100o, a = 0.65 s a, throat
101o to 106o, a = 0.6 s thickness Mz Mx
107o to 113o, a = 0.55 s
Fz, z
114o to 120o, a = 0.5 s +ve values Fx, x
Sign Convention
Penetration
Sign Convention
The sign convention is shown on the screen and in the printed output via sketch as
shown.

The applied point loads Fx, Fy and Fz are positive when acting in the direction of axes.

The applied moments Mx, My and Mz are positive Anti-clockwise when viewed looking
into the origin.

Properties of Fillet Welds

The shape of fillet welds is usually triangular. As shown in the sketch, the outer surface
of a weld is reinforced, i.e. made convex, but in strength calculations this reinforcement
is ignored.
The failure of welds usually occurs in the throat section. This area is therefore used in
strength calculations of welded joints. It is equal to the summation of the throat
thickness multiplied by the weld length.
Other weld properties are also based on the throat area of welds. These properties are
Ix, Iy and Ixy. The origin for these properties is at centroid of the welds and they are
calculated by using x, y coordinates and the throat thickness defined by the user for
each node.

File: WeldCalc20041115-2 Tab: Notes Page 4/8 Date Printed: 2022/2/18

 Welds in Shear, Bending, Torsion and Axial Loading

Formulae for Stress Components

At each node, the components of stress in x, y and z direction are calculated by elastic
analysis, given by:

Fx M z y
fx = -
A Ip
Fy M zx
fy = +
A Ip
Fz M y I x + M x I xy M I + M y I xy
fz = - x+ x y y
A I x I y - I xy
2
I x I y - I xy2
Formulae for Stress Resultants
At each node, the resultant stress fr is calculated. The maximum of these values frmax
is then chosen and placed in the bottom cell.
This maximum stress is meant to be compared with the allowable stress in the weld for
design purposes.

In terms of the adjoining material strength, the allowable stress roughly equal to
py/sqrt(3) (0.55 Us in BS5950-1:20001) and hence implicitly assumed as being pre-
dominently a shear stress.
As induced stresses in the weld can be shear as well as axial, there is a case for
allowing higher stress py in the axial direction. To this end, WeldCalc offers two options
for calculating the maximum stress.

The first option gives a conservative result by not distinguishing between the shear and
the axial stresses. It uses the following stress vector (SRSS, square root of the sum of
squares):

fr = f x2 + f y2 + f z2
The second option is said to give a more realistic estimate of the weld strength. Similar
to the Von Mises definition of the equivalent stress contained in Eurocode3 2, it employs
the following equation:

f z2
fr = f + f +
x
2
y
2

3
In the above two equations fx and fy are shear stresses and fz an axial stress.

As compared to the Eurocode definition of the Von Mises equivalent stress Sqrt
(fz2+3(fx2+fy2), the second fr value has been divided by sqrt(3) to allow weld design
based on its strength in shear rather than axial.

Detailing Requirements for the Design of Welds

The following requirements are based on recommendations contained in Cl 6.7.2 BS
5950-1: 20001. They are intended for guidance only. A user may employ another code
of practice for such requirements.

End Connections Effective Length

Where the ends of an The effective length of a run of fillet weld should be
element is connected only taken as the over all length less one leg length, s, for
by a longitudinal fillet, the each end which does not continue round the corner
length of each weld for a length of 2s, as shown in the sketch.
should be, L >= Tw, the The effective length should be: L >= 4 s
File: WeldCalc20041115-2 Tab: Notes Page 5/8 Date Printed: 2022/2/18
 Welds
length of each in Shear, Bending,
weld Torsion
for a length and
of 2s, as AxialinLoading
shown the sketch.
should be, L >= Tw, the The effective length should be: L >= 4 s
transverse spacing

L >=Tw Length s ignored in

End returns L >=4 t effective length L
Welds terminating at the L >=4 s
ends or sides should be
returned continuously

weld spacing
1

transverse
around the corners for a 1
distance >= 2 s (the weld

Tw
leg length), wherever it is

return >=2s
Weld end
practicable. This detail is
particularly important for
welds in tension due to
bending.
s, leg
length

Lap Joints
Welded end connection showing End Returns
Minimum lap should be: L
Lap & Effective Length Requirements
>= 4t, where t is thickness
of the thinner part.
L >=Tw s, ignored in L
Single fillet weld should
L >=4t
only be used where parts
L >=4s
are restrained to prevent
opening of the joint.

t
Section 1-1

File: WeldCalc20041115-2 Tab: Notes Page 6/8 Date Printed: 2022/2/18

 Welds in Shear, Bending, Torsion and Axial Loading

Describing Weld Group Configuration

First estimate throat thickness for each length of weld in the joint and also select a
convenient point as origin for defining coordinates. Weld group configuration is then
defined by giving part-no, x-coordinate, y-coordinate and throat thickness at each node.

Start using part-no from 1 onwards at first node. When the line of welds becomes
discontinuous or the throat thickness changes, increment the part-no by one for the
node at next weld length.

Six examples are included in the worksheet STORE of this template. They can be
viewed or recalled on the screen by giving their Datastore number from 1001 to 1006
after clicking Get Weld Group Data button. To illustrate data preparation, details of
the first 4 examples are explained below via sketches.

Example 1
This example has 4 parts and 8 Nodes. It represents junction of a UB section welded
at its top and bottom flanges and on either side of its web. To describe fillet weld legs
of 8 and 6 mm, the throat thickness of the horizontal and vertical weld lengths are 5.6
and 4.2 mm respectively.

Weld Details: 288 kN

Part, Node x,y Coordinates & Throat Thickness
Part1, Node 1: -86.6, 182.3, Throat 5.6 y
Part1, Node 2: +86.6, 182.3, Throat 5.6 Part 1
Part2, Node 3: -86.6, -182.3, Throat 5.6 1 2
Part2, Node 4: +86.6, -182.3, Throat 5.6 6 8
Part3, Node 5: -5, +140, Throat 4.2
Part3, Node 6: -5, -140, Throat 4.2
Part 3

Part4, Node 7: +5, +140, Throat 4.2 Part 4 x

Part4, Node 8: +5, -140, Throat 4.2
Applied Loads:
Fy = 288 kN @ zo = 250 mm
5 7
3 4
Part 2

Example 2
This example represents a circular weld of 400 mm diameter and 8 mm fillet weld. It
has 1 Part and 25 Nodes. The first and the last node numbers 1 and 25 are physically
coincident.
Only selected nodes and part data have been shown below for brevity.

Weld Details: Nodes 25, 1

Part, Node x,y Coordinates & Throat Thickness
Part 1, Node 1: 0, 200, Throat 5.6 y
450 kN

Part 1, Node 7: 200, 0, Throat 5.6

Part 1, Node 13: 0, -200, Throat 5.6
Node 7
Node 19

Part 1, Node 19: -200, 0, Throat 5.6

Part 1, Node 25: 0, 200, Throat 5.6 x
Applied Loads: 250,000 kNmm
Fx = 450 kN @ yo = 100 mm & zo = 50 mm
Mz = 250,000 kNmm

Node 13

File: WeldCalc20041115-2 Tab: Notes Page 7/8 Date Printed: 2022/2/18

 Welds in Shear, Bending, Torsion and Axial Loading

Example 3
This example represents a closed trapezoidal weld of 5 mm fillet weld. It has 1 Part
and 5 Nodes. The first and the last node numbers 1 and 5 are physically coincident.

249.5 kN
y
Weld Details:

Nodes 1,5
Part, Node x,y Coordinates & Throat Thickness
Part 1, Node 1: 0, 170, Throat 3.5
Part 1, Node 2: 0, 0, Throat 3.5

Node 4
Part 1, Node 3: 70, 0, Throat 3.5
Part 1, Node 4: 70, 100, Throat 3.5
Part 1, Node 5: 0, 170, Throat 3.5
Applied Loads:
Fy = 249.5 kN @ xo = 49.9 mm

x
Node 2 Node 3

Example 4
This example is an open trapezoidal 8 mm fillet weld having a 5.6 mm Throat
Thickness. It has therefore1 Part and 4 Nodes.

As shown in the sketch below, the weld group represents a 127x64 RSC (rolled steel
channel) welded to the inside flange of a 305 x 205 UC (universal column) section at an
angle. Acting at Centroid of the RSC, the applied axial load of Fy = 300 kN has an
eccentricity of Xo = 62.5 mm and Zo = 19.4 mm. The weld group is therefore subjected
to direct shear, bending and torsion simultaneously.
y
y
300 kN 300 kN

2 z 2

300 kN

Section 2-2 x Plan

y

Weld Details:
Node 2 Part, Node x,y Coordinates & Throat Thickness
300 kN
Part 1, Node 1: 0, 0, Throat 5.6
Part 1, Node 2: 0, 180, Throat 5.6
Node 3 Part 1, Node 3: 127, 60, Throat 5.6
Part 1, Node 4: 127, 0, Throat 5.6
Applied Loads:
Fy = 300 kN @ xo = 62.5 mm and zo = 19.4 mm
x
Node 1 Node 4

References
1 BS 5950: Structural use of steelwork in building
BS 5950-1:2000: Code of practice for design - Rolled and welded sections, 2001
2 DD ENV 1993-1-1: 1992; Eurocode 3: Design of steel structures
Part 1.1 General rules and rules for buildings

WeldCalc20041115 © 2001-4 Dr Shaiq Khan, Techno Consultants Ltd

File: WeldCalc20041115-2 Tab: Notes Page 8/8 Date Printed: 2022/2/18