Calculating torsional stresses in welds that don't fit standard cases

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SUMMARY

This discussion focuses on calculating torsional stresses in welds that do not conform to standard cases outlined in Shigley's Mechanical Engineering Design. The participant faced challenges in determining these stresses due to the unique geometry of the welds and sought advice on effective calculation methods. A suggested approach includes using the formula $$\tau = \frac{T\rho}{J}$$ to approximate stress at the welds, while emphasizing the importance of correlating hand calculations with Finite Element Analysis (FEA) or experimental results for accuracy.

PREREQUISITES
  • Understanding of torsional stress calculations
  • Familiarity with Shigley's Mechanical Engineering Design
  • Knowledge of polar moment of inertia
  • Basic principles of Finite Element Analysis (FEA)
NEXT STEPS
  • Study advanced torsional stress calculation techniques
  • Learn about the polar moment of inertia and its applications
  • Explore Finite Element Analysis (FEA) software for stress analysis
  • Review experimental methods for validating engineering calculations
USEFUL FOR

Mechanical engineers, structural analysts, and students involved in weld design and stress analysis will benefit from this discussion, particularly those facing non-standard geometries in their projects.

Kiblur
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I was required to calculate the torsional stresses on these welds (in green) with the point of rotation G. However this doesn't fit any case in Shigley's so I'm at a loss as to how I should have calculated this. As advised by the teacher, I ended up replacing the keys being welded with full length keys so it would fit a case that I could use. However, that's just bad design. This isn't the first time I've had trouble calculating torsional stress because of an oddly shaped element. Below is another case I encountered. I would like to learn to calculate odd cases like this. Does anyone know of any resources that can help? Thank you very much.

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Kiblur said:
So you have the circumference indicated by the arrow in green welded and then torsion is applied there. I think you can approximate the stress at the welds with the torsion divided by the area of the weld. Another issue is how that torsion will travel through your part. I'd say the most critical section is the space in the middle where only two arms are supporting the load. The section there isn't a cylinder but comes from one. I feel like the results from the formula 3-36 from Shigley's should be somewhat precise.
$$\tau = \frac{T\rho}{J}$$
You'd need to calculate the polar moment of that section but that's doable without too much trouble because of the radial nature of the cross-section.
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Of course, if you have the chance, correlate your hand-made results with FEA. Or even better, with experimental results.
 

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