ch [INTERNATIONAL EpITioncena Machine Frames, Bolted Connections, and Welded Joints ‘orav- ‘The Big Picture : ‘You Are the Designer 20-1 Objectives of This Chapter 20-2 Machine Frames and Structures 20-3 Eccentrically Loaded Bolted Joints 20-4 Welded Joints Sunt the 2.038 iMachine Frames, Bolted Connections, and Welded Joints Discussion Map [3 Asyou devalop the design ‘Discover 3 ‘of machine elements (as Select a variety of products, machines, vehicles, you have throughout his evan toys, Observe how they ara built. What i, book), you must also design shape of the structure that holds everything ogei the housing, frame, oF Wry was that shape chosen by the designer? Wii stricture that supports them funetons are portormed by te frame? and protects thom from tho marinas of ores, bending maments, and torsicrai elements, -moments (lorques) are produced when the products: Gperating? How are they managed and controeg? Vinal thlozd path tha deivers them tothe utiate satu clements while contin coxsidering how these elements must work together in a more comprehensive machine 69 the design progresses, there comes atime when you must put it all together. But thea jg ponents safely, allowing assembly and service while prov Tis impractical to generate a completely general approsch to the design of & 5 tue ora frame for'a machine, a vehicle, a consumer product, or even a toy. Each is diffe cent with regard to its functions; the number, size, and type of components in the prod the intended use; and the expected demand for an aesthetic design. For example, toys of exhibit clever design approaches because the manufacturer wants to provide a sae, fii ticnal toy while minimizing the material used and the amount of personne! time required produce the toy. Inthis chapter you will explore some basic concepts for creating a satisfactory design, considering the shape of structural components, material propestis, the use of fa teners such as bolts, and the fabrication of welded assemblies. You will learn some’of techniques for analyzing and designing bolted assemblies to consider loads on the bol several directions. The design of welded joints to be safe and rigid is discussed. “Chapter 18 covered part of the sor, that dealing with bots loaded in pure tension, a8 ‘alamping function. This chapter extends that chapter to consider eccentrcally loaded joi ‘hose that must resist a combination of direct shear and a bending moment on a bolt patter ‘The ability of « welded joint to camry a variety of loads is discussed with the object ‘of designing the weld, Here both uniformly loaded and eccentrically loaded joins are tented ‘To appreciate the value of such study, select a variety of products, machines, and Yer hisles, and observe how they are built, What is the basic shape ofthe structure that hold ‘everything together? Where are forces, bending moments, and torsional moments (torques) generated? What kinds of stress do they create? Consider the Load path by following a fore, from the place where itis generated through all of the means by which that force or its ef fects are passed to a series of members and to the point where it is supported by a basi frame of the machine or where its delivered out of the system of interest. Considering thé: Toad paths forall forces that exist in @ mechanical device should give you an understanding of the desirable characteristics of the structure and should help you know how to produce: ‘a design that optimizes the management ofthe forces exerted on i. “4Section 20-2 # Machine Frames and Structures 699 “Take apart a variety of mechanical devices to observe their structure, How did shape contribute to the rigidity and safety of the device? Is it rather stiff? Or is it more flexible? ‘Are there ribs or thickened sections to provide special strength or rigidity for certain parte? ‘This chapter will help you identify some efficient approackes to the design of struc- tures and frames and to analyze the performance of fasteners and welded joints loaded in many ways. The subject of machine frames and structures is quite complex. It is discussed feom the standpoint of general principles and guidelines, rather than specitic design tecknigues, CCitical frames are typically designed with computerized finite-element analysis. Also, ex- ih Chapter 16, you weretthe designer of bearings for con- ‘Yeyor systems for a lege product cistrbuton center jon, how do you design the frame and the structure of Live conveyor system? What gonoral form is desirable? materials and shaae should be used fr the stuc- [ural elements? Are tho elements loaded in tension, tompression, bending, shear, torsion, or some combina: sof of those typos fstress? How do the manner of ioad- ‘and the nature of the stress in the structure affect Eshould it be made from steel plate and welded? How boll Using aluminum? Or should it be cast from cast f cast stee!? Can it be molded from plastic? Can }gbites be used? How would the weight of the struc- je'affected? How much rigidity is desirable for this perimental stress analysis techniques are often used to verify designs. kind of structure? What shapes of load-carrying ele- ments contribute to a st, rigid structure, as well as one that s safe in resisting applied stresses? If the structure involves bolting or welding, how are the joints to be designed? What forces, both magnitude and cireetion, must be cartied by the fasteners or the welds? ‘The matarial inthis chaptor will help you make come of these design decisions. Much of the information is {general in nature rather than giving you specific design, Procedures. You must exercise judgment and crestivity rot only in the design of the conveyor frame but also in the analysis of its componente. Because the frame de- ‘sign could evolve into a form too complex for analysis us ing tradtional techniques of stress analysis, you may have to employ finite-element madeling to determine whether the design is adequate or, perhaps, verde signed. Perhaps one or more prototypes should be built for tosting, After completing this chapter, you will be able to: 1. Apply the principles of stress and deflection analysis to propose a reasonable and. efficient shape for a structure or frame and for the components involved. 2, Specify materials that dre well suited to the demands of a given design, given certain conditions of load, environment, fabrication requirements, safety, and esthetics. 3. Analyze eccentrically loaded bolted joints, 4, Design welded joints to carry many types of loading pattems. “The design of machine frames and structures is largely arin thatthe eomponents ofthe ma- chine must be accommodated. The designer is often restricted in where supports can be placed in order not to interfere with the operation ofthe machine or in order to provid: ao- cess for assembly or service.But, ofcourse, there ae technical requirements that must be met as wel for the tureitself Some of the more important design parameters include the following: Strength, Stiffness - Appearance Cost to manufacture Corrosion resistance Weight Size Noise reduction Life ‘Vibration limitation Because of the virtually infinite possiblities for design dotals for frames an lines would depend on the specific application. actors to consider in starting @ des jectfor a frame are now summarized: bearings, pivots, brackets, and feet of other machine elements "© Manner of support of the frame itself Precision of the system: allowable deflection of components = Environment in which the unit will operate * Availablity of analytical tools such as computerized stress analysis, past exbetl cence with similar products, and experimental stress analysis, ™ Relationship to other machines, walls, and so on ‘Again, many of these factors require judgment by the designer. The parameter ed which the designer has the most control are material selection, the geometry of Joti Caryn parts ofthe frame, and manufacturing processes, A review of some possibilities 1 presented below Materials ‘often better to consider more thn just yield strength, ultimate tensile strength, or endurance strength alone. The complete design can be executed in several candidate materials to eval vate the overall performance. Considering the ratio of strength to density, sometimes Te: fered to as the sirength-to-weight ratio ot specific strength, may lead to a different matt ial selection. Indeed, this is one reason forthe use of aluminura, titanium, and compost feria in aircraft, acrospace vehicles, and transportation equipment. 4 Rigidity of a structure ora frame is frequently the determining factor in the desig rather than strength. In these cases, the stiffness of the material, indicated by its mogul of zlasticity is the most important factor. Agein, the ratio of stiffness to density, called specific stiffness, may need to be evaluated. See Table 2-10 and Figures 2-12 and 2-1 for dataad Joints hhe struc- ‘Section 20-2 * Machine Frames and Structures 701 Recommended Deflection Limits ‘Actually, only intimate knowledge of the application of a machine member o a frame can give a value for an acceptable deflection. But some guidelines are available o give you a place to start. (See Reference 3.) Deflection Due to Bending General machine part: 0,000 5 to 0.003 infin of beam length “Maderate precision: 0.000 01 to 0.000 High precision: 0.000 001 to 0.090 01 infin Deflection (Rotation) Due to Torsion General machine part: 0,001° to 0.01°Vin of length. ‘Moderate precision: 0.000 02° to 0.000 4°/in High precision: 0.000 001° to 0.000 02°%in ‘Suggestions for Design to Resist Bending ‘Scrutiny of a table of deflection formulas for beams in bending such as those in Appendix 14 would yield the following form for the deflection: Pe A” KET 0-4) where load length between supports ‘modulus of elasticity of the material in the beam. ‘moment of inertia ofthe cross section of the bear « factor depending on the manner of loading and support Some obvious conclusions from Equation (20-1) are that the Toad and the Tenge should be kept small, dnd the values of E and J should be large. Note the cubic function of the length. This means, for example, that reducing the length by a factor of 2.0 would re- duce the deflection by & facor of 8.0, obviously a desirable effect. Figute 20-1 shows the comparison of four types of beam systems to carry alo, F ata distance, a, from a rigid support. A beam simply supported at each end is taken as the “pasie case.” Using standard beam formulas, we computed the value of the bending mo- iment and the deflection in terms of P and a, and these values were arbitrarily normalized to be 1.0, Then the values forthe three other cases were computed and ratios determined relative to the basic case, The data show that a fixed-end beam gives both the lowest end ing moment and the lowest deflection, while the cantilever gives the highest values forboth, In summary, the following suggestions are made for designing to resist bending 1. Keep the length of the beam as ‘short as possible, and place loads close tothe suport. 2. Maximize the moment of inertia ofthe cross section in the direction of bending. Tn general, you can do so by placing as much of the material as far away from the neutral axis of bending as possible, as in a wide-flange beam or a hollow rectan lar section, 3. Use a material with « high modulus of elasti 4, Use fixed ends for the beam where possible702 FIGURE 20-1 Comparison of methods of supporting ‘load on beam (Robert L. Mott, Applied Strength of Materials; 3806. Englowood Cliffs, NI: Prentice-Hall, 1996) Relive beading monent, My Relive cefleion, ® se use, or casual bumping. 6. Be sure to evaluate the final design with regard te both strength and rigid’ Some approaches to improving rigidity (increasing 1) can actually increase the. stress in the beam because the section modulus is decreased. 7, Provide rigid comer bracing in open frames. 8 Cover an open frame section with a sheet material to resist distonion. THis § process is sometimes called panel stiffening. 9. Consider a truss-type construction to obtain structural stiffness with lightweight. members. triangular parts, an inherently rigid shape. a 11. Consider stiffeners for large panels to reduce vibration and noise. a 12. Add bracing and gussets to areas where loads are applied or at supports to help transfer the forces into adjoining members. 13, Beware of load-carrying members with thin, extended flanges that may be placed it ‘compression, Local buckling, sometimes called crippling or wrinkling, could occu. 14, Place comections at points of low suess if possible. ‘See also References 4-6 for additional design and analysis techniques.ion les sity the This ight Section 20-2 * Machine Frames and Structures 703 FIGURE 20-2 Comparison of torsional deformation as function of shape. Comparison of ‘All ros: eections have the same thickness and perimeter. torsional deformation cay = Angle of twist fora given length and applied torque, as a function of shape. ana CY ea (yChannelshape — (€)Openbollow tube (A) Closedhollow tube. (e) Closed square ube on 28s 010" e= 015" (oy Thinstip Prefered shapes eras ‘ery high values for {Shona gy, FIGURE 20-3 mr = — Comparison of torsional angle of twist, 0, forboxlike frames. Bach has the same basic dimensions and applied torque. * T (a) Conveniional eros brasing Om 108" ‘Suggestions for Design of Members to Resist Torsion ‘Torsion can be created in a machine frame member in a variety of ways: A support surface may be uneven; @ machine or a moter may transmit a reaction torque to the frame; a Ibad acting to the side of the axis of the beam (ar any place away from the flexural center ofthe beam) would produce twisting. In general, the torsional deflection of a member is computed from cra GR (20-2) where T= applied torque or twisting moment L= length over which torque acts G = shear modulus of elasticity of the material R = torsional rigidity constant ° ‘The designer must choose the shape ofthe torsion member carefully to obtain a rgid structure, The following suggestions are made: L. Use closed sections wherever possible. Examples are solid bars with large cross section, hollow pipe and tubing, closed rectangular oF square tubing, and special closed shapes that approximate a tube. be 2, Conversely, avoid open sections made from thin materials. Figure 20-2 shows a dramatic illustration, 3. For wide frames, brackets, tables, bases, and so on, use diagonal braces placed! at 45° to the sides of the frame (see Figure 20-3). ie 4, Use rigid connections, such as by welding members cogether20-3 ECCENTRICALLY LOADED BOLTED JOINTS: FIGURE 20-4 Eccentrically londed olted joint Most of the suggestions made in this sect : the specific type of frame designed: castings made from cast iron, cast sjecnW sini, zine, or magnesium weldments mae from sts o aluminum pt (oi housings from sheet metal or plate; or plastic moldings. References J~ valuable additional guidance as you complete the design of frames, str housings. tended bracket places the bolts in shear because its weight acts directly downward Bt there also exists a moment equal to P X a that must be resisted. The moment ten tate he bracket and thus to shear the bolts. ries the greatest loed. That bolt is then sized. The method will be ilustrated in Protlem 20-1 Te Ateriean lsu of Sse Conrction (AIS) is allowable ssi the damping force’ some of the shear load, is assumed. (See Reference 1.) Jin the design of bolted joints, you should ensure that there are no threads 21 a aate Its ch he te ine Section 20-8 # Eccentrically Loaded Bolted Joints 705 TABLE 20-1 Allowable stresses for bolts Allowable Allowable ASTM grade shear stress tensile sues A307 10. Ksi(69 MPa) 20 Ksi (138 MPa) ‘A325 and AMO 17.5 Ksi (121 MPa) 44 Ksi (203 MPa) A890 22. Kei (152 MPs) 54 Ksi G72. MPa) Example Problem 20-1., Solution For the bracket in Figure 20-4, assume that the total force P is 3.500 Ib and the distance a is 12 in, Design the bolted joint, including the location and number of bolts, the material, and the diameter, ‘The solution shown is an outline of a procedure that can be used to analyze similar joiats. ‘The data of this problem illustrate the procedure. Step 1. Propose the number of bolts and the pattern, This isa design decision, based on yout judgment and the geometry of the connected parts. In this problem, let’ try a pat- tem of four bolts placed as shown in Figure 20-5. Step 2. Determine the direct shear force on the bolt pattern and on each indivicual bolt, assuming that all bolts share the shear load equally: Shear load = P = 3 500 Ib Load per bolt = F, = P/4 = 3 500 Ib/4 = 875 Ib/bolt ‘The shear force acts directly downward on each bolt, Step 3. Compute the moment to be resisted by the bolt pattern: the produc: of the overhanging load and the distance to the centroid of the bolt pattern. In this prob- Jem, M = PX a = (3 500 Ib)(12 in) = 42 000 Ib-in Step 4. Compate the radial distance from the centroid of the bolt pattem tothe cen ter of each bolt In this problem, each bolt has a radial distance of r= VSO in? + 2.00 in} = 2.50 in Step 5. Compute the sum of the squares of all radial distances ¢o all bolts, In this problem, all four bolts have the same r Thea. Ey? = 42.50 in)? = 25.0 in® ‘Step 6. Compute the force on each bolt required to resist the bending moment from 20-3) where 1; = radial distance from the centroid of the bolt pattern to the ith bolt F, = force on the ith bolt due to the moment. The force acts perpendicular to the radius. In this problem, all such forces are equal. For example, for bolt 1, Mr, __ (42.000 Ibvin) 2.50 in) Zr = 42001bFIGURE 20-5 Geometry of bolted joint and forces on bolt 1 Chapter 20 * Machine Frames, Boted Connections, and Well ‘be computed. Lets use the latter approach for this problem. The shear force acts dire ‘ward, inthe y-direction. The a- and »-components of F, are Pre Fy, = Fycos8 ‘The total force in the y-direction is then Fy, + B= 3360 + 875 = 4235 1b ‘Then the resultant force on boli Tis Wpst lok Ry = VOSOEF WBE = 4928. : Step 8, Specify the bolt material; compute the required area forthe bolt and an appropriate size. For this problem, let's specify ASTM A325 steel forthe bolts an allowabie shear stress of 17 500 psi from Table 20-1. Then the required area boltis 2.00 Dimensions inches Bal! Fig 2 52016 L200. —-F a F, = 42001 ate y= 492810 centroid A Fiy 330007 sip (b)Forces on bolt 1Joints nation ‘hor antcan dowa- 20-4 WELDED JOINTS select raving for the ‘Section 20-4 # Welded .oints 707 “The required diameter woud be (i, OI) 7 Y Let's specify « 5/8-in bolt having a diameter of 0.625 in, 0.599 in re “The design of welded joints requires consideration ofthe manner of loading on the joint, the types of materials in the weld and in the members tobe joined, and the geometry ofthe joint itself. The load may be either uniformly distributed over the weld such that all parts of the weld are stessed to the same level, or the load may be eccentrically applied. Both are discussed i this section ‘The materials ofthe weld and the parent members determine the allowable stresses. ‘Table 20-2 lists several examples for steel and aluminum. The allowables listed are for shear on fillet welds. For steel, welded by the electric are method, the type of electrode is an indication ofthe tensile strength ofthe filler metal. For example, the E70 electrode has a minimum tensile strength of 70 Ksi (483 MPa). Additional data are available in pub ica- tions of the American Welding Society (AWS), the American Institute for Steel Constuc- tion (ATSC), andthe Aluminum Association (AA). Types of Joints Joint type refers to the relationship between mating patts a illustrated in Figure 20-6. The batt weld allows a joint to be the same nominal thickness as the mating parts and is usually loaded in tension. If the joint is properly made with the appropriate weld metal, the joint TABLE 20-2 Allowable shear suesses on fillet welds A. Steel Electrode ‘Typical metals Allowable type Joined (ASTM grade) shear sess 60 836, A500 18 Ki (124 MPs) E70 A242, A441 21 Ksi (145 MPa) E80 A572, Grade-65 24 Ki (165 MPa) 50 27 Ki (186 MPa) E100 30 Ksi (207 MPa) BLO 33 Kei (228 MPs) B. Aluminum Filler Alloy 1100 4043 5356 7 5sse ‘Allowable Shear Stress Metal joined Ksi = MPa si © MPa_—Ksi,_— MPx_—Ksi_— MPa 0032 2 48 33 3003 32, 2 30 34 6061 50 34 70 48 as 9 50 34 65 45708 FIGURE 20-6 Types ‘of weld joints FIGURE 20-7 Some ‘types of welds showing ‘edge preparation Ba a4 Tee {Fillet welds (noedge preparation) — 1 =r OO (eySquare butt (0 Single bevel (@Peuble devel >¢ ( Za »¢ s rbot —_—_eoorewh tej LX UD U-eroove butt join, (U-groove with corner joint ‘will be stronger than the parent metal. Thus, no special analysis of the joint is required if the joined members themselves ate shown to be safe. Caution is advised, however, wher the materials to be joined are adversely affected by the heat ofthe welding process. Heat: ‘ueated steels and many aluminum alloys are examples, The other types of joints in Figure. 20-6 are assumed to place the weld in shear. Types of Welds Figure 20-7 shows several types of welds named for the geometry of the edges of the parts to be joined, Note the special edge preparation required, especially for thick plates, to per mit the welding tod to enter the joint and build a continuous weld bead.as ait hen ate Section 20-4 # Welded Joints 709 TABLE 20-3 Allowable shear stresses and forces on welels Base metal Allowable Allowable force ASTM grade Electrode shear siress et inch af le Building type strwctues: 36, Add] 60) 13.600 psi A26, Adal E70 15 800 pst 11 200 bin Bridge-type stectures 36 B60 12.400 psi 8 800 bin AMAL, A242 E70 14.700 psi 10.400 bin Size of Weld ‘The five types of groove-type welds in Figure 20-7 are made as complete penetration welds. Then, as indicated before for butt welds, the weld is stronger than the parent metas, and no further analysis is required, Fillet welds are typically made as equal-leg right triangles, with the size ofthe weld indicated by the length of the leg. A fillet weld loaded in shear would tend to fail along the shortest dimension ofthe weld that isthe line from the root of the weld tote theortical face of the weld and normal to the face. The length of this line is found from simple trigonometry to be 0.707, where w i the leg dimension, The objectives ofthe design ofa fillet welded joint ae wo specify th: length ofthe legs ofthe fille; the pattem of the weld; and the length of the weld, Presented here isthe method that treats the weld as line having no thickness. The method involves dete-min- ing the maximum force per inch of weld leg length. Comparing the actual force with an al towable force allows the calculation of the required leg length, ‘Table 20-3 gives data forthe allowable shear stress and te allowable force per inch for some combinations of base metal and welding electrode. In general, the allowables for building-type structures are for steady loads. The values for bridge-type loading accounts for the cyclic effects. For tr fatigue-type repeated loading, refer tothe literature. (See Ref- erences ? and 3.) Method of Treating Weld as a Line Four different types of loading are considered here: (1) direct tension ar compression, (2) ditect vertical shear, (3) bending, and (4) twisting. The method allows the desigrer to perform cafculations in a manner very similar to that used to design the load-carrying rem. bers themselves. In general, the weld is analyzed separately for each type of loading t de- termine the force per inch of weld size due to each load, The loads are then combined vee~ ‘orially fo determine the maximum force. This maximum force is compared with the allowables from Table 20-3 to determine the size of the weld required, ‘The relationships used are summatized next: Formula (and Equation Number} ‘Type of Loading for Force per Inch of Weld Direct tension or compression f= P/A,, (20-4) Direct vertical shear (20-5) Bending, Twisting (20-6) (20-7)FIGURE 20-8 Geometry factors for weld analysis 710 of ° ‘ac vouon: $= SPE Lae ne i rer al? ‘Weld bp i! mae Soe bd + a3 Weldall pe Weld at roan ron e mt Key aye nanTABLE 20-4 Minimum weld sizes for thick plates | | Section 20-4 # Welded Joints m Plate thickness Minitourn leg size for (in) filet weld (in) <1 316 | Pins Ws S34 sas pores WB oud 12 >6 58 Jn these formulas, the geometry of the weld is used to evaluate the terms A,» Sy. and Jao using the relationships shown in Figure 20-8. Note the similarity between these for- mula and those used to perform the stress analysis. Note, also, the similarity between the geometry factors for welds and the properties of areas used for the stress analysis. Because the weld i treated as a line having no thickness, the units for the geometcy factors are df= ferent from those of the area properties, a indicated in Figure 20-8, | ‘The use of this method of weld analysis willbe demonstrated with example problems. In general, the method requires the following steps: 1, Propose the geometry of the joint and the design of the members to be joined, 2. Identify the types of stresses to which the joint is subjected (bending, twisting, vertical shear, direct tension, or compression). - 3. Analyze the joint co determine the magnitude and the ditection of the force on the ‘weld due to each type of load. 4. Combine the forces vectorially atthe point or points of the weld where the forces ‘appear to be maximum. 5. Divide the maximum force on the weld by the allowable force from Table 20-3 10 determine the required leg size for the weld, Note that when thick plates are welded, there are minimum acceptable sizes for the welds as listed in Table 20-4 Example Problem 20-2 Design a bracket similar to that in Figure 20-4, but use welding to attach the bracket 1 the. f ‘column, The bracket is 6.00 in high and is made from ASTM A36 steel having a thickness ‘of 1/2 in, The column is also made from A36 steel and is 8.00 in wide. Solution ‘Step I. The proposed geometry is a design decision and may have to be subjected to some iteration to achieve an optimum design. For a firs tral, let's use the C-shaped weld E pattern shown in Figure 20-9. : Step 2. ‘The weld will be subjected to direct vertical shear and twisting caused ty the 3 500-Ib losd on the bracket. S) Stop 3. To compute the forces on the weld, we must know the geometry factors A, and J, Also, the location of the centroid of the weld patter must be computed (see Fig- ture 20-9(b)]. Use Case 5 in Figure 20-8. : A, = 2b + d= 24) +6= Min b+ ar Po + dP _ (14)? _ LeCloy G+) 2 a 1144 in?Force Due to Vertical Shear V=P=35001 fe = Pf, = (3.500 Ib)/14 in = 250 tbvin ‘This force acts vertically downward on all parts of the weld. Forces Due to the Twisting Moment. T= P{8.00 + (b ~ 3) = 3 500{8.00 + 4.00 ~ 1.14)) T = 3 500(10.86) = 38 010 Ib-in The twisting moment causes 2 force to be exerted on the weld that is perpeidig to aradiel line from the centroid of the weld pattern tothe point of interest. In this cai combine all such components to compate the resultant force: _ Tey _ @8.010)3.00) . nT 144 perl Te, _ 8 010)(2.86) Fey _ G8 0100.86) n= Te = sso tvin 20-9(6). Thus, the maximum force is 1 560 Ibyin. FIGURE 20-9 » Leo (C-shaped weld bracket “co0% ie stop! ¢ | Twisting P= 3 001 HL] Poin of JP moment manmum) poe 7 force 3 d= 6.00 £ Wate centroid of weld pattern Plate, 1/26 (©) Basic design oF bracket (0) Dimensions of bracket ine ‘Vector summation of Jov= 950 anit forces on point Sg = 1560: of maximum force (© Analysis of forces‘lar the to ae Section 20-4 = Welded .oinis m3 ‘Step 5. Selecting an £60 electrode for the welding, we find that he allowable force ppet inch of weld leg size is 9 600 Ib/in (Tuble 20-3), Then the required weld leg size is = 1560 fin "= F600 Ibn per in of leg ‘Table 20-4 shows that the minimum size weld for a 1/2-in plate is 3/16 in (0.188in). ‘That size should be specified. 163 in Example Problem 20-3 A steel strap, 1/4 in thick, is to be welded to a rigid frame to carry a dead load of 12 500 1b, Solution FIGURE 20-10 Steel strap as shown in Figure 20-10, Design the strap and its weld. ‘The basic objectives of the design are to specify a suitable material forthe strap, the weld ing electrode, the size of the weld, and the dimensions W and i, as shown in Figure 20-10. Let's speeify that the strap is to be made from ASTM A441 structural steel and that itis to be welded with an E70 electrode, using the minimum size weld, 3/16 in. Appeadix 7 gives the yield strength of the A441 steel as 42 000 psi. Using a design factor of 2, weean compute an allowable stress of 9 = 42 000/2 = 21 000 psi ‘Then the requited area of the strap is PB 500 Ib Gg, ~ 21 000 ibiin® But the area is 1V Xt, where = 0.25 in. Then the required width Wis w Alt = 0595/0. Let's specify that W = 2.50 in, To compute the required length of the weld /, we need the allowable force on the 3/16-in weld. Table 20-3 indicates the allowable force on the A441 steel welded witt an E70 electrode to be 11 200 lbvin per in of leg size. Then 11.200 Ibn 10 in leg 595 in? 38in X 0.188 in leg = 2.100 Ibvin The actual force on the weld is fo™ Ply, = Pl2h Mele ASTM Atal steel, P= 12500112.5008 22 100 tb/in) 2.98 in Let’ specify h = 3.00 i, Efample Problem 20-4 Evahote tho design shown in Figure 20-11 with regard to stress inthe welds, Allpars : thesatembly are made of ASTMA36 structural steel and are welded with an 0 cle ‘The 2 500-Ib load is a dead load. in Figure 20-12. The offset location of the load canses a twisting on the weld that produces ‘force on the weld toward the leit in the y-direction. The bending produces a fore fj, ing outward along the x-axis. The vertical shear force f, acts downward along the 2 From statics, the resultant of the thee force components would be fee With th Nov each component force on tho weld will be computed, FIGURE 20-11 Bracket assembly ‘4inSchedule 40 steel pipe Soe | a FIGURE 20-12 Ke= ITM bg Forve vectors fv» O25 big, Jo = 2201 vin Vector summation: hot hit te Val = A+ TEEReferences m5 Te Jn T = (2.500 1b)(8.00 in) = 20 000 Ib-in © OD? = 45002 = 2.25 in J, = (mY ODY'M4 = (m4.500)/4 = 71.57 in? Then 629 thin Bending Force, f, he 4M = (2 500 IbX14.00 in) = 35000 Ibn S,, = (M(OD)*/4 = (m\(4.500)7/4 = 15.90 in® Then 35.000 f SO 2201 tin 5 Vertical Shear Force, f, a ar} 4 (m(OD) = (}(4.500 in) = 14.14 in 2500 vA FAG = 177 vin [Now the resultant can be computed | Sea MEARE be fa = VO +220" + 177 = 2.296 tovin Comparing this with the allowable force on a 1.0-in weld gives 2.296 vin = 0.239 in REFERENCES |. Amesican Intute of Steel Construction. Monuat of Steet Gonsirucron. Oth ed. New York: American Institue of Steel Consirution, 1989, 2 Blodget, Omer W. Design af Welded Structures. Cleve- ‘lend, OH: James F Lincoin Are Welding Foundation, 1966. jp Blodget, Omec W. Design of Weldment, Cleveland, OH: ‘ames F Lincoln Are We ding Foundation, 1963. 5600 Ibn per in of leg size ‘The 1/4-in fillet specified in Figure 20-11 is satisfactory. Marshak, Kurt M. Design of Machine and Struetural Pets ‘New York: John Wiley & Sons, 1987. Mott, Robert L. Applied Strength of Materials. 34 ed. Up- ‘er Saddle River, NJ: Prentice-Hall, 1996. Slocum, Alexander H. Precision Machine Design. Upper Saddle River, NI Prentice-Hall, 1992, Weiser, Peter ed Stel Casting Handbook. Sth ed. Recky River, OM: Stee! Founder's Society of America, 1980,716 PROBLEMS For Problems 1-6, design a bolted joint to join the two mem- bers shown in the appropriate figure. Specify the number of bolts the patie, the bolt grade, ad the bolt size. 1 Figure 20-13 bx axin Ee Ly chert ie da sin wpa = 120001 FIGURE 20-13 (Problems 1,7, and 13) —feiv2in Lox 4x12 steel angles Kegan 0-16 Rigid support sin ‘ypieal Each hanger caries 790 FIGURE 20-14 (Problem 2) ya 2in—+| x13 steel channel FIGURE 20-15 (Problem 3) ‘Chapter 20 = Machine Frames, Bolted Connections, and We 4, Figure 20-16 de vainvat 1x2 ‘Stee! section Enlarged of joint area FIGURE 20-16 (Problems 4 and 8) 5, Figure 20-17 6, Figure 20-18 Problems ‘eating he jot in, and ue te llowable ores pein of leg for bulding-type tructues from Table 20-3, 1, igre 20-13, 8, Figure 20-16 9, Figure 20-17 10, Figure 20-18 UL, Figure 20-19 12, Figure 20-19 (out Py = 0) For Problems 13-16, design a welded joint to join two aluminum members shown in the appropriate figue: Specify the weld pater, the typeof ile alloy, andthe sizeof ‘Weld. The types of materials joined are lise inthe problem 13, Figure 20-13: 6061 alloy (out P= 4 00016) 14, Figure 20-20: 6061 slloy 1S, Figure 20-21: 6083 alloyJoints eww. veld pat weld. in roblems Rigid £ Ke Toit sy [oie (10inf—10in-} (oom 2 500th dint} FIGURE 20-17 (Problems 5 and » (C10 % 20 channet Sting af asin ott Load shared equally by four brackes (only two shown) FIGURE 20-18 (Problems 6 and 10) (Problems 11 and 12) 4A 1] | Totatosd = 1 5006 uniformly distributed Ar actuckle Icebietensica 00 Ip Weld SK" Grote are FIGURE 20-21 (Problem 15)8 16. Figure 20-22: 3003 alloy “Total load 10-000 > “shared by wo supPOTS] FIGURE 20-22 (Problem 16) Weld st ‘around ‘of 4 800th fi is made from (@) AISIAT203 AIST 5160 OQT 1300 see; ()alemibuen © shuminam 7075-T6; (2) Gasiue 6A)-4V, Gi auc (9 ttanium 3A1-13V-11Cé, aged, Use © 2a i vil strength eeA-52 19. Life = 48900 hous 21, Life = 25 300 hours 23, Life = 47 200 hours CHAPTER 15. No practice problems CHAPTER 16. Plain Surface Bearings All problems inthis chapter are desiga problems for which no ‘unique solutions exist. CHAPTER 17 Power Screws and Ball Screws 5, 212-3 Acme thread 6. L>123in 1. P=6FiaIin 8. 7=37121 11, Lead angle = 4.72"; self-locking 12. Eificiency = 35% 13, mo 180 rpm; P = 0.866 hp 17. 243 years CHAPTER 18 Fasteners 4, Grade 2 bots: 516-18; 7 = 70.3 Ibn 5. F= 11901 6, F=423kN 7, Nearest metric thread is M24 x 2. Metric thread is 1.8 mm larger (89 large). 8, Closest standard thread ie MS X 0.8. (#10-32 is also lose.) 9. 3.61 KN 10. 1171 = 2385 1b 2862 Ib & 1081 1b i. 20671b kab CHAPTER 19 Springs 1, k= 133 1bfin 2 by= 1.497 in 3, Fy= ATS Ibs Ly= 1.25in 7, ID= 093 i; Dy = 1.015 ing C = 11.94; N = 6 6 coils 8. C= 8.49; = 0.241 in; pitct angle = 8.70%; L, = 1.12in 9. Fy = 10.25 Ts stress = 74 500 psi 11, OD = 0.583 in when at solid length 12, F, = 26.5 lb; stress = 189 300 psi (Htigh) 31. Bending stress = 114 000 psi torsion stress = 62.600 psi. Stresses are safe 35, Torque = 0.91 Ib-in to rotate spring 180°. Stress = 184 800 psi; OK fo: severe service CHAPTER 20 Machine Frames, Bolted Connections and Welded Joints Problems 1-16 are design problems for which there aréhe. ‘nique stations. « 1. Weight Diameter tbper inch ‘Material in) of length) a 1020 HR steel 0.638 0.0906 . Aluminum 2014-16 0451 0.9160 c.TH6AL-AV (Aged) 0285 0.0102 CHAPTER 21. Electric Motors 13. 480V, 3-Phase because the current would be lower and the motor size smaller 16. n, = 1800 pm in the United States 500 spam in France 17, 2Bole motor; n = 3.600 spm at er0 load (approximate) 18, nz 12.000 pm 19, 1725 rpm and 1 140 rpm 20, Variable frequency controt 34, a. Single phase, eplit phase AC motor v. T= 41.41bin ©. T= 617 Ibin 4. T= 144 Ton 35. b, T= 12.6Nm ©. T= 189Nm a 1Nm 39, Ful load speed = synchronous speed = 720 pm 47, Use aNEMA Type K SCR control to convert 115 VAC to 190 VDC; use 2 90 VBC motor 51. Speed theoretically increases to infinity 92, T= 205 Nm 54, NEMA? starter 55. NEMA I starter CHAPTER 22 Motion Control: Clutches and Brakes 5. Data from Problem 1: 7 = 1801bin Date from Problem 3: T= 27.4 Ibn 8 T= 143 Ibe 3.6 bf 1, T= 223618 15. F,= 1091 17. W= 1381 18, b> 16.0in