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SOLUTION (11.1)
Known: Two steel plates with Sy = 50 ksi are joined using transverse-loaded fillet
welds. Each weld is 4-inches long. E60 series welding rods are used, and good
welding practice is followed. A force of 33,000 lb is applied. The safety factor is 3.0.

Find: Determine the minimum leg length that must be used.

Schematic and Given Data:

F =33,000 lb

A D

B C

E60 series welding rods

Sy = 50 ksi (plates)
F =33,000 lb
SF = 3.0
h = ? in.

Assumptions:
1. The throat length is given by t = 0.707 h.
2. The weld efficiency is 100%.
3. The critical stress is at the minimum throat section, where the area is tL. This
cross section carries the entire load F in shear.

Analysis:
1. With throat length, t = 0.707 h, the throat area, A = (0.707)(8)h = 5.66h in.2
2. From Section 11.4, estimated yield strength of the weld is
S y = 60 ksi - 12 = 48 ksi

3. From the distortion-energy theory, Sys = (48)(0.58) = 27.84 ksi.

2
S ysA (27.84 ksi)(5.66h in. )
4. F= or 33,000 lb = . Thus, h = 0.63 in. ■
SF 3.0
11-1
Comment: Because of assumption 3, the solution is less rigorous.

11-2
SOLUTION (11.2)
Known: Two steel plates with Sy = 50 ksi are joined using transverse-loaded fillet
welds. Each weld is 4-in. long. E70 series welding rods are used, and good welding
practice is followed. A force of 33,000 lb is applied. The safety factor is 3.0.

Find: Determine the minimum leg length that must be used.

Schematic and Given Data:

F =33,000 lb

A D

B C

E70 series welding rods

Sy = 50 ksi (plates)
F =33,000 lb
SF = 3.0
h = ? in.

Assumptions:
1. The throat length is given by t = 0.707 h.
2. The weld efficiency is 100%.
3. The critical stress is at the minimum throat section, where the area is tL. This
cross section carries the entire load F in shear.

Analysis:
1. With throat length, t = 0.707 h, the throat area, A = (0.707)(8)h = 5.66h in.2
2. From Section 11.4, estimated yield strength of the weld is
S y = 70 ksi - 12 = 58 ksi

3. From the distortion-energy theory, Sys = (58)(0.58) = 33.64 ksi.

2
S ysA (33.64 ksi)(5.66h in. )
4. F= or 33,000 lb = . Thus, h = 0.52 in. ■
SF 3.0
11-3
Comment: Because of assumption 3, the solution is less rigorous.

11-4
SOLUTION (11.3)
Known: Two steel plates with Sy = 425 MPa are butt welded together with E70 series
welding rods. The weld length is known.

Find: Determine the maximum tensile load that can be applied to the joint with a safety
factor of 4.

Schematic and Given Data:

F F

17 mm

Weld length = 90 mm
S y = 425 MPa
SF = 4
E70 series weld

Assumption: The weld efficiency is 100%.

Analysis:
1. From Section 11.4, the weld rod has a yield strength of

S y = (70 - 12) ksi 6.89 MPa = 399.6 MPa

ksi

Since 399.6 < 425 the weld should yield first.

2. With the assumed 100% efficiency, the maximum tensile load that can be applied
is
S yA (399.6 ! 10 6 N/m 2)(0.017 m)(0.09 m)
F= = = 152.8 kN
SF 4 ■

11-5
SOLUTION (11.4)
Known: Two steel plates are butt welded using E60 series welding rods. The safety
factor is 3.

Find: Determine the tensile load that can be applied to the plates per inch of welded
plate width.

Schematic and Given Data:

F F

0.50 in.
S y = 52.5 ksi (plate)
SF = 3
E60 series weld

Assumption: The weld efficiency is 100%.

Analysis:
1. From Section 11.4 the weld rod has a yield strength of Sy = (60 - 12) ksi = 48 ksi.
Since 48 ksi is less than Sy of the plates, the weld will yield first.
2. With the assumed 100% efficiency:
S yA (48, 000 psi)(0. 50 in. )(L)
F= =
SF 3

3. The maximum tensile load per inch of weld is F/L = 8000 lb/in. ■

Comment: The load that the plate can carry per inch of length is given by F = SyA =
(52,500)(0.50) = 26,250 lb which significantly exceeds that of the weld.

11-6
SOLUTION (11.5)
Known: Two steel plates are welded with a convex fillet weld.

Find: Estimate the static load, F, that can be carried by the joint.

Schematic and Given Data:

A D

B C 50 mm
7 mm

7 mm

F
Sy = 350 MPa (plate)
h = 5 mm
SF = 3

Assumptions:
1. The plates themselves do not fail; shear failure occurs in the weld throat area.
2. The throat length is given by t = 0.707 h.
3. The weld efficiency is 100%.

Analysis:
1. With the assumed throat length, t = 0.707 h, the weld throat area is
(0.707)(5)(100) = 353.5 mm2 for the two welds.
2. The weld throat area is stressed in shear. Using the distortion-energy theory,
Ssy = 0.58 Sy = 203 MPa.
3. F = SsyA/SF = (203)(353.5)/3 = 23,920 N, or 23.9 kN ■

Comment: If the top plate has a cross-sectional area A = (40)(7) = 280 mm2, then the
load capacity of the plate is F = SyA = 350(280) = 98 kN which significantly exceeds
that of the weld; i.e., the plate will not fail.

11-7
11-8
SOLUTION (11.6)
Known: Two steel plates with Sy = 400 MPa are butt welded together with E70 series
welding rods. The weld length is known.

Find: Determine the maximum tensile load that can be applied to the joint with a safety
factor of 3.

Schematic and Given Data:

F F

15 mm

Weld length = 90 mm
S y = 400 MPa
SF = 3
E70 series weld

Assumption: The weld efficiency is 100%.

Analysis:
1. From Section 11.4, the weld rod has a yield strength of

Sy = (70 - 12) ksi 6. 89 MPa = 399. 6 MPa

ksi
Since 399.6 < 400 the weld should yield first.
2. With the assumed 100% efficiency, the maximum tensile load that can be applied
is
S A (399. 6 ! 106 N/m2)(0. 015 m)(0. 09 m)
F= y = = 179. 8 kN
SF 3 ■

11-9
SOLUTION (11.7)
Known: Two steel plates are butt welded using E60 series welding rods. The safety
factor is 3.

Find: Determine the tensile load that can be applied to the plates per inch of welded
plate width.

Schematic and Given Data:

F F

3/8 in.
S y = 50 ksi (plate)
SF = 3
E60 series weld

Assumption: The weld efficiency is 100%.

Analysis:
1. From Section 11.4 the weld rod has a yield strength of Sy = (60 - 12) ksi = 48 ksi.
Since 48 ksi is less than Sy of the plates, the weld will yield first.
2. With the assumed 100% efficiency:
SyA (48, 000 psi)(3/8 in. )(L)
F= =
SF 3

3. The maximum tensile load per inch of weld is F/L = 6000 lb/in. ■

Comment: The load that the plate can carry per inch of length is given by F = SyA =
(50,000)(.375) = 18,750 lb which significantly exceeds that of the weld.

11-10
SOLUTION (11.8)
Known: Two steel plates are welded with a convex fillet weld.

Find: Estimate the static load, F, that can be carried by the joint.

Schematic and Given Data:

A D

B C 50 mm
8 mm

8 mm

F
Sy = 350 MPa (plate)
h = 5 mm
SF = 3

Assumptions:
1. The plates themselves do not fail; shear failure occurs in the weld throat area.
2. The throat length is given by t = 0.707 h.
3. The weld efficiency is 100%.

Analysis:
1. With the assumed throat length, t = 0.707 h, the weld throat area is
(0.707)(5)(100) = 353.5 mm2 for the two welds.
2. The weld throat area is stressed in shear. Using the distortion-energy theory,
Ssy = 0.58 Sy = 203 MPa.
3. F = SsyA/SF = (203)(353.5)/3 = 23,920 N, or 23.9 kN ■

Comment: If the top plate has a cross-sectional area A = (40)(8) = 320 mm2, then the
load capacity of the plate is F = SyA = 350(320) = 112 kN which significantly exceeds
that of the weld; i.e., the plate will not fail.

11-11
SOLUTION (11.9)
Known: Two steel plates are joined using 3/8 in. parallel-loaded fillet welds. The yield
strength, Sy, and the length of the welds are known. The safety factor is 3.

Find: Determine the maximum tensile load that can be applied.

Schematic and Given Data:

A D

B C 3.0 in.

E60 series welding rods

F Sy = 50 ksi (plates)

h = 0.375 in.
SF = 3

Assumptions:
1. The throat length is given by t = 0.707 h.
2. The weld efficiency is 100%.

Analysis:
1. With t = 0.707 h, the throat area = (0.707)(3/8)(6) = 1.59 in.2.
2. From Section 11.4, the yield strength of the weld material is
Sy = 60 - 12 = 48 ksi.
3. Using the distortion energy theory, Ssy = 0.58 Sy = 0.58(48) = 27.8 ksi.
4. Thus, F = SsyA/SF = (27,800)(1.59)/3 = 14,700 lb. ■

11-12
SOLUTION (11.10D)
Known: Two steel plates with given yield strength are butt welded together.

Find: Design a butt welded joint that can transmit a tensile load of 6000 lb.

Schematic and Given Data:

F F

3/8 in.
S y = 50 ksi (plate)
SF = 3
E60 series weld

Decisions:
1. Select two 3/8 in. thick steel plates with 1 in. width.
2. Employ a safety factor of 3.
3. Use E60 series welding rods.

Assumption: The weld efficiency is 100%.

Analysis:
1. From Section 11.4 the weld rod has a yield strength of Sy = (60 - 12) ksi = 48 ksi.
Since 48 ksi is less than Sy of the plates, the weld will yield first.
2. With the assumed 100% efficiency:
S yA (48,000 psi)(3/8 in.)(1)
F= =
SF 3

3. The maximum tensile load for the weld is 6000 lb. ■

Comment: The load that the plate can carry per inch of width is given by F = SyA =
(50,000)(.375) = 18,750 lb which significantly exceeds that of the weld.

11-13
SOLUTION (11.11D)
Known: Two steel plates are joined using 3/8 in. parallel-loaded fillet welds. The yield
strength, Sy, and the loads the welds can carry are known.

Find: Design a parallel-loaded fillet weld joint that can transmit a load greater than
14,000 lb.

Schematic and Given Data:

A D

B C 3.0 in.

E60 series welding rods

F Sy = 50 ksi (plates)

h = 0.375 in.
SF = 3

Decisions:
1. Select two plates at least 3/8 in. in thickness.
2. Employ a safety factor of 3.
3. Use E60 series welding rods.
4. Use a weld length of 3 in. (6 in. total).

Assumptions:
1. The throat length is given by t = 0.707 h.
2. The weld efficiency is 100%.
3. The steel plate(s) does not fail in tension.

Analysis:
1. With t = 0.707 h, the throat area = (0.707)(3/8)(6) = 1.59 in.2.
2. From Section 11.4, the yield strength of the weld material is
11-14
 Sy = 60 - 12 = 48 ksi.

3. Using the distortion energy theory, Ssy = 0.58 Sy = 0.58(48) = 27.8 ksi.
4. The maximum tensile load that can be applied is F = SsyA/SF =
(27,800)(1.59)/3 = 14,700 lb. ■

Comments:
1. The capacity achieved is slightly greater than required.
2. This design is only one of several possible.

SOLUTION (11.12)
Known: Two steel plates are joined using transverse-loaded fillet welds. Each weld is
100 mm long. A force of 150 kN is applied. The safety factor is 3.5.

Find: Determine the minimum leg length that must be used.

Schematic and Given Data:

F =150 kN

A D

B C

E70 series welding rods

F = 150 kN Sy = 400 MPa (plates)
SF = 3.5
h = ? mm

Assumptions:
1. The throat length is given by t = 0.707 h.
2. The weld efficiency is 100%.

11-15
3. The critical stress is at the minimum throat section, where the area is tL. This
cross section carries the entire load F in shear.

Analysis:
1. With throat length, t = 0.707 h, the throat area, A = (0.707)(200) h = 141.4h mm2
2. From Section 11.4, estimated yield strength of the weld is

Sy = 70 ksi - 12 = 58 ksi = 58 ksi 6. 89 MPa = 399.6 MPa.

ksi
3. From the distortion-energy theory, Sys = (399.6)(0.58) = 231.8 MPa.
SysA (231. 8 MPa)(141. 4h mm2)
4. F= or 150, 000 N = . Thus, h = 16.0 mm. ■
SF 3. 5

Comment: Because of assumption 3, the solution is less rigorous.

SOLUTION (11.13)
Known: A bracket supports a total load of 60 kN. E60 series welding rods are used
with a safety factor of 3.0.

Find: Determine the weld size that should be specified.

Schematic and Given Data:

y
y

60 kN

100 mm

Vertical 100 mm
weld on inside of
both plates along
the y-axes
E60 series welding rod
SF = 3.0
55 mm 75 mm Note: Each plate has
two 75 mm welds and
one 100 mm weld.

11-16
Assumptions:
1. The direct (transverse) shear stresses are uniformly distributed over the length of
all welds.
2. The parts being joined are completely rigid.
3. The throat length is t = 0.707 h.

11-17
Analysis:
1.
T(52.5)/J = 199.2/t
75 mm

T(50)/J = 189.6/t A 189.6/t

B
30,000 N
per side 100 mm
85.34/t y
G
199.2/t

x
C D
189.6/t
189.6/t
T(22.5)/J = 85.34/t

2. Calculating the center of gravity, G, of the weld-segment.

100 t (0) + 75 t (37. 5) + 75 t (37. 5)
x = !A ixi = = 22. 5 mm
!A 250 t
y = 50 mm (by symmetry)
3. The polar moment of inertia of the weld pattern about G is the polar moment of
inertia of one vertical plus the two horizontal welds.
3 3
J = Jv + 2Jh = 100 t + 100 t(22. 52 + 0) + 2 75 t + 75t (502 + 152)
12 12
J = 613,020t mm4
4. T = (30,000 N)(55 mm + 22.5 mm) = 2.325 ✕ 106 N•mm
Torsional stress components are shown in the above figure at A, B, C, and D.
30, 000 N 120
Direct shear adds a downward vector of V = = at each location.
A (250 mm)t t
Thus, the highest resultant stress is at C.
5. At C, ! = 1 189. 62 + (85. 34 + 120)2 = 280. 9
t t
6. From Section 11.4, Sy = Su - 12 ksi = 60 - 12 = 48 ksi. From the distortion-energy
theory,
Sys = 0. 58 Sy = 0. 58(48) = 27. 84 ksi = 27. 84 ksi 6. 89 MPa = 191. 9 MPa
ksi
S
280. 9 = ys = 191. 9 ; t = 4. 39 mm
7.
t SF 3
h= t = 4. 39 = 6. 21 mm
0. 707 0. 707
Conservatively we use h = 7 mm. ■

11-18
Comment: For calculating transverse shear and axial stress, the throat dimension t is
assumed to be in a 45˚ orientation. But the throat dimension t is assumed to be in the
plane of the weld pattern when computing torsional stresses. Also, for calculating the
weld dimension h, t is assumed to be in a 45˚ plane. This simplification although not
theoretically correct is justified for most engineering applications.

SOLUTION (11.14)
Known: A bracket supports a 4000 lb load. A fillet weld extends for the full 4 in.
length on both sides. Series E60 welding rod is used. The safety factor is 3.0.

Find: Calculate the minimum weld size required.

Schematic and Given Data:

4000 lb
4 in.

3 in.

SF = 3.0
E60 series welding rod

Assumptions:
1. The throat length is given by t = 0.707 h.
2. The weld efficiency is 100%.

Analysis:
1. The stress due to direct shear is given by:
! = V = 4000 lb = 500
A 8t t
2. The stress due to bending is given by:
! = Mc where
I
M = (3 in.)(4000 lb) = 12,000 lb.in
11-19
 3 3 12, 000(2) 2249. 3
I = 2 L t = 2 4 t = 10. 67t in. 4; c = 2 in. Therefore, ! = =
12 12 10. 67 t t
3. Vectorally adding σ and τ: Resultant stress = 1 5002 + 2249. 32 = 2304
t t
4. From Section 11.4 in the text, Sy = 60 - 12 = 48 ksi. Using the distortion-energy
theory, Sys = 0.58 Sy = 0.58(48) = 27.84 ksi

5. 2304 = Sys = 27, 840 ; t = 0. 25 in.

t SF 3. 0
6. Since t = 0.707 h, h = t = 0. 25 = 0. 35 in. ■
0. 707 0. 707

SOLUTION (11.15)
Known: A part welded using an E60 welding rod has out-of-plane eccentric loading.
The safety factor is 3.

Find: Determine the weld size required if only the top of the joint is welded.

Schematic and Given Data:

X
70 A

60 mm

120 mm
X D
Force applied
10 kN at midpoint of
C cylindrical
160 mm
hole

E60 series welding rod

SF = 3.0
Sy = 345 MPa

Assumptions:
1. The direct shear stresses are uniformly distributed over the length of all welds.
2. The parts being joined are completely rigid.
3. The throat length is t = 0.707 h.

11-20
4. The absence of weld CD in Fig. 11.9 will not alter the bending stresses; that is
there is a weld at AB and CD -- see analysis 1.
5. The weld at CD is absent and bending occurs at axis X-X -- see analysis 2.
6. Bending occurs at CD rather than at axis X-X -- see analysis 3.

Analysis 1:
1. With welds assumed at AB and CD, the moment of inertia of the welds is
Ix ≈ 2Ih = 2(70) t (60)2 = 504,000 t
1, 600, 000(60) 190. 5
2. Bending stress on weld AB is ! = Mc = = MPa
I 504, 000 t t
10, 000 142. 9
Transverse stress on weld AB is ! = V = = MPa
A 70t t
As in Fig. 11.9b, the resultant stress !R = 1 190. 52 + 142. 92 = 238
t t
3. Using the distortion-energy theory, Sys = 0.58 Sy = 0.58(345) = 200.1 MPa

4. 238 = Sys = 200. 1 ; t = 3. 57 mm

t SF 3
5. Since t = 0.707 h, h = t = 3. 57 mm ; h = 5. 05 mm ■
0. 707 0. 707

Analysis 2:
1. In this analysis we assume that the neutral bending axis is at the center of the cross
section. Therefore for weld AB, Ix ≈ Ih = (70)(t)(60)2 = 252,000 t
1, 600, 000(60) 380. 9
2. Bending stress on weld AB is ! = Mc = = MPa
I 252, 000 t t
10, 000 142. 9
Transverse stress on weld AB is ! = V = = MPa
A 70t t
As in Fig. 11.9b, the resultant stress !R = 1 380. 92 + 142. 92 = 406. 8
t t

3. Using the distortion-energy theory, Sys = 0.58 Sy = 0.58(345) = 200.1 MPa

4. 406. 8 = Sys = 200. 1 ; t = 6. 1 mm

t SF 3

5. Since t = 0.707 h, h = t = 6. 1 mm ; h = 8. 63 mm ■
0. 707 0. 707
Analysis 3:
1. In this analysis we assume that the bending axis is at the bottom edge CD of the
cross section. Therefore for weld AB, Ix ≈ Ih = (70)(t)(120)2 = 1,008,000 t
11-21
 1, 600, 000(120) 190. 5
2. Bending stress on weld AB is ! = Mc = = MPa
I 1, 008, 000 t t
10, 000 142. 9
Transverse stress on weld AB is ! = V = = MPa
A 70t t
As in Fig. 11.9b, the resultant stress !R = 1 190. 52 + 142. 92 = 238
t t
3. Using the distortion-energy theory, Sys = 0.58 Sy = 0.58(345) = 200.1 MPa

4. 238 = Sys = 200. 1 ; t = 3. 57 mm

t SF 3

5. Since t = 0.707 h, h = t = 3. 57 mm ; h = 5. 05 mm ■
0. 707 0. 707

Comments:
1. It is not conservative to assume that bending would tend to occur closer to CD than
to X-X since this assumption would end in the calculation of a smaller weld (leg)
size. However, in practice bending most probably would take place closer to CD
than to X-X.

2. With the omission of the bottom weld CD, there is an increase in the direct shear
stress carried by the upper weld whereas the bending stress is not affected
significantly. Even in the absence of the lower weld, the compressive stress at the
bottom is carried by the support.

SOLUTION (11.16)
Known: Two steel plates are butt welded together. Both the plate and welding
materials have known strength properties. The imposed loading fluctuates rapidly
between -20 kN and +60 kN. The safety factor is 2.5.

Find: Estimate the length of weld required:

(a) If the weld "reinforcement" is not removed.
(b) If the excess weld material is carefully ground off so as to provide a smooth,
continuous surface.

Schematic and Given Data:

11-22
 F F

S u = 500 MPa 20 mm

S y = 400 MPa

SF = 2.5

Assumptions:
1. If the weld "reinforcement" is not removed, the weld metal has a rough surface
comparable to an as-forged surface.
2. The gradient factor, CG = 0.8
3. Infinite life (106 cycles) is required

Analysis (a):
1. With the assumption that CS for the weld metal corresponds to "as-forged",
CS = 0.52. Also CG = 0.8.
2. Using Eq. (8.1) and Table 8.1,
Sn = Sn'CLCGCSCTCR = (500/2)(1)(0.8)(0.52)(1)(1) = 104 MPa
3. Nominal load values: Pm = 20, Pa = 40. Design overload (SF = 2.5):
Pm = 50 kN; Pa = 100 kN.
!a P
= a = 2
!m Pm
104
overload point
100
!a = 91 MPa
80
! (MPa)

life
8
a

0
0 100 200 300 400 500
!
m (MPa)

11-23
4. From the above diagram, σa = KfPa/A = 1.2(100,000)/A = 91 MPa
A = 1319 mm2 = (20 mm)L; L = 66 mm ■

Analysis (b):
1. With the assumption that CS for the weld corresponds to a ground surface, CS= 0.9.
2. Sn = Sn'CLCGCSCTCR = (500/2)(1)(0.8)(0.9)(1)(1) = 180 MPa
!a Pa
!m = Pm = 2

180
150 ! a = 150 MPa
! (MPa)

life

8
120
a

80

40

0
0 100 200 300 400 500
!
m (MPa)

3. From the above diagram,

σa = Kf Pa/A = 1.0(100,000)/A = 150 MPa. Therefore, A = 667 mm2.
Also, A = (20 mm)L. Hence, L = 33.33 mm. Conservatively, L = 34 mm. ■

SOLUTION (11.17D)
This problem is left for the student to solve. A reference that will provide an excellent
start for a solution is given in "Properties and Uses of 43 Adhesives Classified
According to Chemical Type," N.J. DeLollis, p. 28-31, Product Engineering Design
Manual, edited by Douglas C. Greenwood, McGraw-Hill, New York, 1959.

SOLUTION (11.18D)
This problem is left for the student to solve. A reference that will provide an excellent
start for a solution is given in "Which Adhesive For What," R.W. James and R.W.
Gormly, p. 32-33, Product Engineering Design Manual, edited by Douglas C.
Greenwood, McGraw-Hill, New York, 1959.

SOLUTION (11.19D)
Known: Adhesive bonding of aluminum is touted as a comparatively new joining
process for joining aluminum to aluminum or to other materials. Apparently the result

11-24
is strongly dependent on joint design, choice of adhesive, surface preparation and the
bonding process.

Find: List advantages and disadvantages of adhesive bonding.

Analysis:
1. Adhesive bonding of aluminum is a comparatively new joining process.

2. The developments in this area have resulted in the use of adhesive bonding for
joining aluminum to aluminum or to other materials.

3. The resulting bond strength is strongly dependent on joint design, choice of

adhesive, surface preparation and the bonding process.

4. Some advantages of adhesive bonding are:

* Uniform stress distribution over the entire bonded area

* Good fatigue resistance
* Good vibration damping and flexibility
* Ability to bond aluminum to non-metallic materials
* Weight reduction compared to bolt and rivet joints
* Smooth joint surfaces and contours
* Ability to anodize with no risk of staining
* Prevention or reduction of galvanic corrosion
* Good sealing and insulating properties ■

5. Some disadvantages of adhesive bonding are:

* Decreased strength at elevated temperatures, especially under long time loading

* Possible degradation of bond by environmental influence

* Complicated bonding process. Stronger joints demand proper surface preparation and
may also require jigs, presses and heating equipment
* Difficult and expensive to provide for adequate inspection
* Additional exhaust and protective clothing might be necessary for reasons of health
■

Comment: The following internet reference provides additional information:

http://www.alu-info.dk/Html/alulib/modul/A00489.htm
http://www.alu-info.dk/Html/alulib/modul/A00490.htm

11-25
SOLUTION (11.20)
Known: Figure P11.20 shows two mating members that are adhesively bonded. The left
member is loaded with a downward force as shown in Figure P11.20, and in fig. 1 below.

Find: Redesign the left member for increased load capacity. Consider the force flow
concept and comment on the advantages and disadvantages of a redesigned joint

Schematic and Given Data:

1. Original design of left member 2. Redesign of left member

Assumptions:
1. The two members are adhesively bonded.
2. The width (into the page) of each member is uniform.
3. The load is in the direction shown, and the member where the external force is
applied generally retains its shape.

Design Analysis:
1. A taper on the top portion of the left member will allow for a more gradual flow of
force into the right (thicker) member and would avoid the end stress concentration
that is present in the original design. A disadvantage of the taper design would be
increased fabrication cost.

2. Extending the length of the left member and wrapping it around the top of the right
(thicker) member would allow the force to flow through the top contact points
(mechanically load) along with flowing through the adhesive bond. This redesign
would substantially increase the joint strength. The main disadvantage of this
design would be increased material and part cost.
11-26
Comment: Tensile stresses and stress concentrations in the adhesive bond can result in
peeling and eventual failure of the joint.

11-27
SOLUTION (11.21)
Known: Figure P11.21 shows two mating members that are adhesively bonded through a lap
joint. The joint is loaded with horizontal and vertical forces as shown in the figure.

Find: Redesign the thinner member to increase the joint strength, better resist the
applied forces, and reduce the chance of peel and separation.

Schematic and Given Data:

1. Original design of thinner member 2. Redesign of left member

Assumptions:
1. The two members are adhesively bonded.
2. The width (into the page) of each member is uniform.
3. The load is in the direction shown, and the member on whom the external force is
applied generally retains shape.

Design Analysis:

1. The redesigned joint includes a horizontal leg to better resist moments at the joint,
like the moment created by the applied horizontal force. This horizontal leg also
doubles the bonded area and increases shear and tension capacity of the joint.
Tapering each leg allows for a more gradual force flow and avoids stress
concentrations and the resultant peeling that may occur.
2. A radius was designed into the root of the horizontal leg in order to avoid a stress
concentration from the moment created by the horizontal applied force.

Comment: It is helpful to draw a free body diagram of the externally loaded member
and then determine the forces and moments at the adhesive joint. Tensile stresses and

11-28
stress concentrations in the adhesive bond can result in peeling and eventual failure of
the joint.

11-29
SOLUTION (11.22)
Known: Figure P11.22 shows two mating members that are adhesively bonded through a
butt joint. The joint is loaded with horizontal and vertical forces as shown in the figure.

Find: Redesign the thinner member to increase the joint strength, better resist the
applied forces, and reduce the chance of peel and separation.

Schematic and Given Data:

Original design
Assumptions:
1. The two members are adhesively bonded.
2. The width (into the page) of each member is uniform.
3. The load is in the direction shown, and the member on whom the external force is
applied generally retains shape.

Design Analysis:

11-30
Redesign
1. The redesigned joint includes horizontal legs extending upwards and downwards to
better resist moments at the joint like the one created by the applied (alternating)
vertical forces. These legs also greatly increase the bonded area, which in turn
increases shear, and tension capacity of the joint. Each leg could be tapered which
allows for a more gradual force flow and avoids stress concentrations and the
resultant peeling that may occur.

2. A radius was designed into the root of the horizontal leg on both sides in order to
avoid a stress concentration from the moment created by the vertically applied
forces.

Comment: It is helpful to draw a free body diagram of the externally loaded member
and then determine the forces and moments at the adhesive joint. Tensile stresses in the
adhesive bond can result in peeling and eventual failure of the joint.

11-31
SOLUTION (11.23)
Known: Figure P11.23 shows two mating members that are adhesively bonded. The right
member is loaded with a vertical force downward as shown in the figure.

Find: Redesign the right member for increased load capacity by means of improved
adhesive bonding. Consider the force flow concept and comment on the advantages and
disadvantages of a redesigned joint.

Schematic and Given Data:

Original design of right member Redesign of right member

Assumptions:
1. The two members are adhesively bonded.
2. The width (into the page) of each member is uniform.
3. The load is in the direction shown, and the member on whom the external force is
applied generally retains shape.

Design Analysis:
1. By rotating the right member we can improve the chance of peeling in the adhesive
bond. The vertical force in Figure P11.23 creates a moment and stress concentration
at the top edge of the adhesive bond. By flipping the right member the peeling stress
is reduced at the top edge of the adhesive bond. Also, the applied moment in the
improved joint serves to better compress the adhesive bond.
2. The improved joint will better carry the applied load without separation, and the
redesign has no obvious disadvantages when compared to the original design.

Comment: It is helpful to draw a free body diagram of the externally loaded member
and then determine the forces and moments at the adhesive joint. Tensile stresses in the
adhesive bond can result in peeling and eventual failure of the joint.

11-32
SOLUTION (11.24)
Known: Figure P11.24 shows an aluminum angle adhesively bonded to a rigid vertical
member. The angle is horizontally loaded as shown in the figure.

Find: Redesign the angle to increase the joint strength, better resist the applied forces,
and reduce the chance of peel and separation.

Schematic and Given Data:

Original design
Assumptions:
1. The two members are adhesively bonded.
2. The width (into the page) of each member is uniform.
3. The load is in the direction shown, and the member on whom the external force is
applied generally retains shape.

Design Analysis:

Redesign
1. The redesign shown above (on the left) incorporates a c-channel at the base of the
angle that fits over the rigid member. This increases the force and moment carrying
capacity of the adhesive bond as it is supplemented by mechanical/structural
interlocking. This design will help the joint perform as if the rigid member and
aluminum angle were a continuous section. The new joint design would be highly
resistant to joint separation or peeling.

11-33
2. A simpler option – shown above on the right -- would be to move the aluminum
angle to the other side of the rigid member. This allows for the adhesive bond to be
in compression and reduces any chance of peeling. The aluminum angle takes part
of the loading mechanically. This joint design would be resistant to joint separation
or peeling regardless of the adhesive bond strength (with no bending of the vertical
(assumed rigid) member.

Comment: It is helpful to draw a free body diagram of the externally loaded member
and then determine the forces and moments at the adhesive joint. Tensile stresses in the
adhesive bond can result in peeling and eventual failure of the joint.

11-34
SOLUTION (11.25)
Known: Figure P11.25 shows two members adhesively bonded together. The right-angled
member is loaded as shown in the figure.

Find: Redesign the right member for increased load capacity by means of improved
adhesive bonding. Consider the force flow concept and comment on the advantages and
disadvantages of a redesigned joint.

Schematic and Given Data:

Original design Redesign

Assumptions:
1. The two members are adhesively bonded.
2. The width (into the page) of each member is uniform.
3. The load is in the direction shown, and the member on whom the external force is
applied generally retains shape.

Design Analysis: The redesigned joint moves the angled member to the left side of the
vertical cantilevered member. This reduces the chance that the top leading edge of the
adhesive bond will separate/peel. The redesign also puts the adhesive bond into a
compression/shear loading scheme and is an improvement with respect to the
tensile/peel stresses developed at the top leading edge of the original design.

Comment: It is helpful to draw a free body diagram of the externally loaded member
and then determine the forces and moments at the adhesive joint. Tensile stresses in the
adhesive bond can result in peeling and eventual failure of the joint.

11-35