Technical Note on Software for ME 487 Report No. UM-MEAM-91-01 Instructor: Prof. Kannatey-Asibu Jr. Author: Chih-Kuo Fang

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Technical Note on Software for ME 487 Instructor: Prof. Kannatey-Asibu Jr. Author: Chih-Kuo Fang 1. ABSTRACT An interactive software package on a Macintosh for ME487 is developed, which involves the thermal analysis of weldments, calculation of residual stresses and distortion, and design of weldments. This technical note provides an overview of the software, and gives step-by-step instructions. Following these procedures, students can use this software easily even when not familiar with the Macintosh, and save a lot of time on the calculations of various aspects of welding problems. 2. INTRODUCTION This software can solve three aspects of welding problems: A. Thermal Analysis of Weldments: Analysis of temperature distribution and cooling rate is an essential aspect of any welding problems, since these affect the final structure of the material as well as the stresses and distortion induced. Simplified closed form analyses have been undertaken. B. Residual Stresses and Distortion: The analyses under thermal aspects are extended to include residual stresses and distortion. Since this area is still in its infancy in research, the software developed only encompasses simplified closed form solutions. C. Design of Weldments: The design of weldments involves the determination of weld size (crossectional area and length). This software provides a useful tool for students when designing welding systems for application. Hence the software is divided into the following sections: (1) crossectional area of fused zone (2) temperature distribution (3) peak temperature (4) determining thin or thick plate (5) cooling rate (6) solidification rate (7) bead width (8) residual stress (9) weld distortion (10) weldment design

3. STEP-BY-STEP INSTRUCTIONS 1. If you use a Macintosh SE computer, swich on the machine. If you use a Macintosh II, IIx, IIcx, or IIci computer, press the upper rightmost key (marked by a triangle) on the keyboard. 2. Insert the diskette containing the software for ME487. 3. Double click the " ME487 apl " icon to open the file. You will see: ME487 WELDING SOFTWARE MAIN MENU 1) CROSSECTIONAL AREA OF FUSED ZONE 2) TEMPERATURE DISTRIBUTION 3) PEAK TEMPERATURE 4) DETERMINING THIN OR THICK PLATE 5) COOLING RATE 6) SOLIDIFICATION RATE 7) BEAD WIDTH 8) RESIDUAL STRESS 9) WELD DISTORTION 10) WELDMENT DESIGN 0) EXIT ENTER NUMBER? 4. Enter the corresponding number of the item of interest. 5. Follow the instructions on the screen to response. Be careful of the data type (real or interger) when you enter your input data. If the default value is real, you should enter real data also. Example: If you see: WELD DENSITY (kg/m^3)? (e.g. 8000.0) where "8000.0" is the default value. If the value which you are going to enter is the same as the default value, just press <return>, otherwise, you should enter your data, say "5000.0" instead of "5000" to avoid errors. 4. DEMONSTRATION Aw = crossectional area of fused zone C = specific heat d = root opening E = voltage h = plate thickness I = current

K = thermal conductivity Ko = modified Bessel function of the 2nd kind and order zero L = latent heat of fusion 1 = weld length P = applied load Q = heat input ql =energy required to melt a unit volume of material R = distance from the fusion zone to the point of interest = Iyl-w/2 r = distance from the arc to the point of interest S = (total) shrinkage So = first pass shrinkage T = temperature of the point of interest Tm = melting temperature To = ambient temperature t, = solidification time V = welding velocity W = accumulated weight of weld metal deposited per unit weld length W0 = initial W ( first pass ) w = bead width a = K/PC CA = measured strain (from srrain gauge A) gB = measured strain (from srrain gauge B) Ec = measured strain (from srrain gauge C) Ex = strain in x-direction Cy = strain in y-direction C1,2 = principal strain P = weldment density Pw = weld density'1) = poission's ratio Tmax = maximum shear stress Tl1 = heat transfer efficiency q12 = melting efficiency (1) Crossectional Area of Fused Zone A 1122EI qlV where q1= Pw [ L + C (Tm-T0) ]

(2) Temperature Distribution For thick plate ( 3-Dimensional ) T-To= Q -v (r+x 2rT-To rK e 2a For thin plate (2-Dimensional) Q -vx -vx T-To = 2crK e 2a Ko( 2a ) (3) Peak Temperature 1 4.13PhVCR 1 T-To Q Tm-To (4) Determining Thin or Thick Plate T =h PCV (T-To) Q Thin plate when T < 0.6 Thick plate when T > 0.9 (5) Cooling Rate For thick plate ( 3-Dimensional ) dT -2icKV dt Q (T-To)2 For thin plate (2-Dimensional) dT =-27lKPC(V)2 (T-To)3 (6) Solidification Rate LQ 27LKPCV(T- Tm)2 (7) Bead Width For thick plate ( 3-Dimensional ) Vw Q = 1.25 7CwKTm (0.4 + 4- )

For thin plate ( 2-Dimensional) Q = 8KhTm (0.2 + VW ) (8) Residual Stress EA = ~x Cos2A + sin2 (A + Yy sinxy sin cos2 EB = EX COS2 0B + Ey sinxy sin OS2B E = E cos2 0c + ~y sin2 0c +xy sin 0A cos20c EX +CY 1 cx- )2 + 2 12, ~X2 2 -E 2+xy E -O1 = - -U2 ( E1 +') E2) E 2 = -1 2 (~2+ 1) E) Tmax =I1 - 02 1 / 2 (9) Weld Distortion (1) Transverse Shrinkage (a) Butt Welds For Single Pass A S=a h +pd where a = 0.2 for inch units ( 5.16 for mm units ) For Multipasss Weld S = SO + b logW b =constant (b) Fillet Welds S= a Leg of Fillet Plate thickness (inches) a = 0.06 for lap-joint, 0.04 for T-joint (2) Longitudinal Shrinkage 0. 12IL S= 125 (inches) 105h

(3) Angular Distortion =l[ 0.25 - ( -o.5)2 ] 4O Eh3 h4 where -= 2D, D= C= 1+-IC 12(1 -2)' 1 +0.2W (10) Weldment Design (1) Butt Welds P P h hl' (2) Fillet Welds For Tension Test = 0.707h 1 where h = weld leg For Torsion Test Direct shear 1 = P / A Where A = throat area Shear due to torsion 2 = Tr / J where T = Torque = PL J = area polar moment of inertia of weld group about centroid For Bending Test Direct shear 1 = P/A MC Bending Stress o = I whereM=PA, C=d/2+h I = 0.707 h Iu Iu = unit area moment of inertia

APPENDIX

PROGRAM ME487 DOUBLE PRECISION BK,BI,BJ,RKK,SS,A,EX, THK 1 WRITE (9,10) 10 FORMAT ('********************************************'//'; ME487 WELDING SOFTWARE' /'; iMAIN MENU'/ I;...... — /' 1) CROSSECTIONAL AREA OF FUSED ZONE' 2) TEMPERATURE DISTRIBUTION /' 3) PEAK TEMPERATURE' 4) DETERMINING THIN OR THICK PLATE'/' 5) COOLING RATE' 6) SOLIDIFICATION RATE'; 7) BEAD WIDTH'/; 8) RESIDUAL STRESS'' 9) WELD DISTORTION'/; 10) WELDMENT DESIGN'/;.....................................I / 0) EXIT'/'ENTER NUMBER?'/) PI=3.1415926 11 FORMAT (/A50) 21 FORMAT (F9.4) 22 FORMAT (F12.5) 20 READ (9,30) I 30 FORMAT (I2) GO TO (100,200,300,400,500,600,700,800,900,1000) I GO TO 9999 C —----------------------- NO.1 —----------------------------------- 100 WRITE (9,11)'HEAT TRANSFER EFFICIENCY? (e.g. 0.95)' READ (9,21) Fl IF (F1.EQ.0.) F1=.95 WRITE (9,11)'MELTING EFFICIENCY? (e.g. 0.97)' READ (9,21) F2 IF (F2.EQ.0.) F2=.97 WRITE (9,11)'WELD DENSITY (kg/m^3)? (e.g. 8000.0)' READ (9,22) THO

IF (THO.EQ.0.) THO=8000. THO=THO/1000000000. WRITE (9,11)'SPECIFIC HEAT (kJ/kg.K)? (e.g. 0.850)' READ (9,22) C IF (C.EQ.0.) C=.85 C=C*1000 WRITE (9,11)'LATENT HEAT (kJ/kg)? (e.g. 272.0)' READ (9,21) HL IF (HL.EQ.0.) HL=272. HL=HL*1000. WRITE (9,11)'MELTING TEMPERATURE (C)? (e.g. 1465.0)' READ (9,21) TM IF (TM.EQ.0.) TM=1465. WRITE (9,11)'AMBIENT TEMPERATURE (C)? (e.g. 20.0)' READ (9,21) TA IF (TA.EQ.0.) TA=20. WRITE (9,11)'CURRENT (Amp)? (e.g. 250.0)' READ (9,21) EI IF (EI.EQ.0.) EI=250. WRITE (9,11)'VOLTAGE (Volts)? (e.g. 30.0)' READ (9,21) E IF (E.EQ.0.) E=30. WRITE (9,11)'WELDING SPEED (mm/s)? (e.g. 12.0)' READ (9, 22) V IF (V.EQ.0.) V=12. Q=THO* (HL+C* (TM-TA)) AW= (F1*F2*E*EI) / (Q*V) WRITE (9,190) AW 190 FORMAT (/'CROSSECTIONAL AREA =' F10.3, I (mm^2)1/) PAUSE GO TO 1 C —-----------------— NO. 2 —------------------------------------- 200 WRITE (9,11)'ENTER DIMENSION? (2=THIN PLATE, 3=THICK PLATE)' READ (9,202) I IF (I.EQ.0) I=2 202 FORMAT (I1) WRITE (9,11)'THERMAL CONDUCTIVITY (J/s.mm.C)? ( e.g. 0.05)' READ (9,21) THK IF (THK.EQ.0.) THK=.05

WRITE (9,11)'AMBIENT TEMPERATURE (C)? (e.g. 25.0)' READ (9, 21) TA IF (TA.EQ.0.) TA=25. WRITE (9,11)'WELD DENSITY (kg/m^3)? (e.g. 8000.0)' READ (9,22) THO IF (THO.EQ.0.) THO=8000. THO=THO/1000000000. WRITE (9,11)'SPECIFIC HEAT (kJ/kg.K)? (e.g. 0.850)' READ (9,21) C IF (C.EQ.0.) C=.85 C=C*1000. ALPHA=THK/(THO*C) WRITE (9,11)'WELDING SPEED (mm/s)? (e.g. 10.0)' READ (9, 21) V IF (V.EQ.0.) V=10. WRITE (9,205) 205 FORMAT ( /'ENTER HEAT-INPUT OR VOLTAGE-CURRENT?','1=HEAT-INPUT, 2=VOLATGE-CURRENT') READ (9,30) K IF (K.EQ.0) K=1 GO TO (206,207) K 206 WRITE (9,11)'HEAT INPUT (J/s)? (e.g. 6000.0)' READ (9,22) Q IF (Q.EQ.0.) Q=6000. GO TO 209 207 WRITE (9,11)'VOLTAGE (Volts)? (e.g. 30.0)' READ (9,21) E IF (E.EQ.0.) E=30. WRITE (9,11)'CURRENT (Amp)? (e.g. 200.)' READ (9,21) EI IF (EI.EQ.0.) EI=200. WRITE (9,11)'HEAT TRANSFER EFFICIENCY? (e.g. 1.0)' READ (9,21) Fl IF (F1.EQ.0.) F1=1. Q=F1*E*EI 209 WRITE (9,210) 210 FORMAT (/'COORINATES W.R.T. HEAT SOURCE. X (mm)=? (e.g. -8.0)'; /' I!! X<0 IF BEHIND THE HEAT SOURCE') READ (9,21) X IF (X.EQ.0.) X=-8.0

WRITE (9,11)'Y (mm) =? (e.g. 5.0)' READ (9,21) Y IF (Y.EQ.0.) Y=5.0 IF (I.NE.3) GO TO 270 C —-----------------— 3-D WRITE (9,11)'Z (mm)=? (e.g. 3.0) READ (9,21) Z IF (Z.EQ.0.) Z=5.0 R=(X**2+Y**2+Z**2)**. 5 EX=-V* (R+X)/ (2.*ALPHA) T=Q/(2.*PI*R*THK)*EXP(EX) + TA WRITE (9,265) T 265 FORMAT (/'3-D TEMPERATURE =' F8.3,' (C)') PAUSE GO TO 1 270 IF (I.NE.2) GO TO 1 C —-------------------- 2-D WRITE (9,11)'THICKNESS (mm) =? (e.g. 8.0) READ (9,22) H IF (H.EQ.0.) H=8.0 R= (X**2+Y**2) **.5 EX=V*X/(2.*ALPHA) A=V*R/(2.*ALPHA) BI=0 BJ=0 DO 295 K=1,70 RKK=1 SS=O DO 285 I=1,K RKK-RKK*I S=I SS=SS+1./S 285 CONTINUE RK=K BI=BI+1. / (RKK*RKK) * ((A/2. ) ** (2.*RK) ) BJ=BJ+ (A/2. ) ** (2. *RK)) / (RKK*RKK) *SS 295 CONTINUE BK=- (DLOG (A/2.) +0.5772157) * (BI+1. ) +BJ T=Q/(2. *PI*THK*H) *EXP (-EX) *BK+TA

WRITE (9,299) T 299 FORMAT (/'2-D TEMPERATURE =' F8.3,' (C)') PAUSE GO TO 1 C —------------------------— NO. 3 —---------------------------------- 300 WRITE (9,11)'MELTING TEMPERATURE (C)? (e.g. 1500.0)' READ (9,21) TM IF (TM.EQ.0.) TM=1500. WRITE (9,11)'AMBIENT TEMPERATURE (C)? (e.g. 25.0)' READ (9,21) TA IF (TA.EQ.0.) TA=25. WRITE (9,11)'WELD DENSITY (kg/m^3)? (e.g. 8000.0)' READ (9,22) THO IF (THO.EQ.0.) THO=8000. THO=THO/1000000000. WRITE (9,11)'SPECIFIC HEAT (kJ/kg.K)? (e.g. 0.850)' READ (9,22) C IF (C.EQ.0.) C=.85 C=C*1000. ALPHA=THK/(THO*C) WRITE (9,11)'WELDING SPEED (mm/s)? (e.g. 10.0)' READ (9, 21) V IF (V.EQ.0.) V=10. WRITE (9,305) 305 FORMAT (/'ENTER HEAT-INPUT OR VOLTAGE-CURRENT?',;'1=HEAT-INPUT, 2=VOLATGE-CURRENT') READ (9,30) K IF (K.EQ.0) K=1 GO TO (306,307) K 306 WRITE (9,11)'HEAT INPUT (J/s)? (e.g. 6000.0)' READ (9,22) Q IF (Q.EQ.0.) Q=6000. GO TO 309 307 WRITE (9,11)'VOLTAGE (Volt)? (e.g. 30.0)' READ (9,21) E IF (E.EQ.0.) E=30. WRITE (9,11)'CURRENT (Amp)? (e.g. 200.)' READ (9,21) EI IF (EI.EQ.0.) EI=200. WRITE (9,11)'HEAT TRANSFER EFFICIENCY? (e.g. 1.0)'

READ (9,21) F1 IF (F1.EQ.0.) Fl=l. Q=F1*E*EI 309 WRITE (9,11)'THICKNESS(mm) =? (e.g.8.0) READ (9, 21) H IF (H.EQ.0.) H=8. WRITE (9,11)'DISTANCE FROM FUSION ZONE (mm)? (e.g. 3.42) READ (9,21) R IF (R.EQ.0.) R=3.42 TI= 4.13*THO*H*V*C*R/Q + 1/(TM-TA) TP= TA + 1./TI WRITE (9,390) TP 390 FORMAT (/'PEAK TEMPERATURE =' F10.3,' (C)') PAUSE GO TO 1 C —----------------------— NO.4 —------------------------------------- 400 WRITE (9,11)' TEMPERATURE (C)? (e.g. 600.0)' READ (9,21) T IF (T.EQ.0.) T=600. WRITE (9,11)'AMBIENT TEMPERATURE (C)? (e.g. 25.0)' READ (9,21) TA IF (TA.EQ.0.) TA=25. WRITE (9,11)'WELD DENSITY (kg/m^3)? (e.g. 7000.0)' READ (9,22) THO IF (THO.EQ.0.) THO=7000. THO=THO/1000000000. WRITE (9,11)'SPECIFIC HEAT (kJ/kg.K)? (e.g. 0.50)' READ (9,21) C IF (C.EQ.0.) C=.5 C=C*1000. ALPHA=THK/(THO*C) WRITE (9,11)'WELDING SPEED (mm/s)? (e.g. 6.0)' READ (9, 21) V IF (V.EQ.0.) V=6. WRITE (9,405) 405 FORMAT (/'ENTER HEAT-INPUT OR VOLTAGE-CURRENT?' ~;'~1=HEAT-INPUT, 2=VOLATGE-CURRENT' ) READ (9,30) K IF (K.EQ.0) K=2

GO TO (406,407) K 406 WRITE (9,11)'HEAT INPUT (J/s)? (e.g. 6750.0)' READ (9,22) Q IF (Q.EQ.0.) Q=6750. GO TO 409 407 WRITE (9,11)'VOLTAGE (Volt)? (e.g. 30.0)' READ (9,21) E IF (E.EQ.0.) E=30. WRITE (9,11)'CURRENT (Amp)? (e.g. 250.)' READ (9,21) EI IF (EI.EQ.0.) EI=250. WRITE (9,11)'HEAT TRANSFER EFFICIENCY? (e.g. 0.9)' READ (9,21) Fl IF (F1.EQ.0.) F1=.9 Q=F1*E*EI 409 WRITE (9,11)'THICKNESS (mm)=? (e.g.3.0) READ (9,21) H IF (H.EQ.0.) H=3. TAU=H* (THO*C*V* (T-TA)/Q) **0.5 WRITE (9,460) TAU 460 FORMAT (/' TAU =' F6.3) IF (TAU.LT.0.6) THEN WRITE (9,11)'THIN PLATE' ELSE IF (TAU.GT.0.9) THEN WRITE (9,11)'THICK PLATE' ELSE WRITE ( 9, 11)' UNDETERMINED' ENDIF PAUSE GO TO 1 C —----------------------— NO.5 —------------------------------------- 500 WRITE (9,11)' TEMPERATURE (C)? (e.g. 400.0)' READ (9,21) T IF (T.EQ.0.) T=400. WRITE (9,11)'AMBIENT TEMPERATURE (C)? (e.g. 30.0)' READ (9,22) TA IF (TA.EQ.0.) TA=30. WRITE ( 9, 505 ) 505 FORMAT (/'ENTER HEAT-INPUT OR VOLTAGE-CURRENT?', ~;'1=HEAT-INPUT, 2=VOLATGE-CURRENT')

READ (9,30) K IF (K.EQ.0) K=2 GO TO (506,507) K 506 WRITE (9,11)'HEAT INPUT (J/s)? (e.g. 6375.0)' READ (9,22) Q IF (Q.EQ.0.) Q=6375. GO TO 509 507 WRITE (9,11)'VOLTAGE (Volt)? (e.g. 30.0)' READ (9,21) E IF (E.EQ.0.) E=30. WRITE (9,11)'CURRENT (Amp)? (e.g. 250.)' READ (9,21) EI IF (EI.EQ.0.) EI=250. WRITE (9,11)'HEAT TRANSFER EFFICIENCY? (e.g. 0.85)' READ (9,21) Fl IF (F1.EQ.0.) F1=.85 Q=F1*E*EI 509 WRITE (9,11)'THERMAL CONDUCTIVITY (J/s.mm.C)? ( e.g. 0.0456)' READ (9,22) THK IF (THK.EQ.0.) THK=.0456 WRITE (9,11)'WELDING SPEED (mm/s)? (e.g. 8.0)' READ (9, 21) V IF (V.EQ.0.) V=8. WRITE (9,11)'ENTER DIMENSION? (2=THIN PLATE, 3=THICK PLATE)' READ (9, 30) I IF (I.EQ.0) I=2 IF (I.NE.3) GO TO 550 C —3-D DT=-2*PI*THK*V/Q* (T-TA) **2 WRITE (9,520) DT 520 FORMAT (/'COOLING RATE =' F10.3,' (C/s)') PAUSE GO TO 1 550 IF (I.NE.2) GO TO 1 C —2-D WRITE (9,11)'WELD DENSITY (kg/m^3)? (e.g. 7870.0)' READ (9,22) THO IF (THO.EQ.0.) THO=7870. THO=THO/1000000000.

WRITE (9,11)'SPECIFIC HEAT (kJ/kg.K)? (e.g. 0.595)' READ (9,21) C IF (C.EQ.0.) C=.595 C=C*1000. WRITE (9,11)'THICKNESS (mm) =? (e.g.9.0)' READ (9,22) H IF (H.EQ.0.) H=9. DT=-2.*PI*THK*THO*C*(V*H/Q)**2*(T-TA)**3 WRITE (9,599) DT 599 FORMAT (/'COOLING RATE =' F10.3,' (C/s)' ) PAUSE GO TO 1 C —----------------------— NO.6 —------------------------------------- 600 WRITE (9,11)'SPECIFIC HEAT (kj/kg.K)? (e.g. 0.5)' READ (9,21) C IF (C.EQ.0.) C=.5 C=C*1000. WRITE (9,11)'LATENT HEAT (j/kg)? (e.g. 2.5)' READ (9,21) HL IF (HL.EQ.0.) HL=2.5 WRITE (9,11)'MELTING TEMPERATURE (C)? (e.g. 1600.0)' READ (9,21) TM IF (TM.EQ.0.) TM=1600. WRITE (9,11)'AMBIENT TEMPERATURE (C)? (e.g. 25.0)' READ (9,21) TA IF (TA.EQ.0.) TA=25. WRITE (9,605) 605 FORMAT (/'ENTER HEAT-INPUT OR VOLTAGE-CURRENT?''1=HEAT-INPUT, 2=VOLATGE-CURRENT') READ (9,30) K IF (K.EQ.0) K=2 GO TO (606,607) K 606 WRITE (9,11)'HEAT INPUT (J/s)? (e.g. 6750.0)' READ (9,22) Q IF (Q.EQ.0.) Q=6750. GO TO 609 607 WRITE (9,11)'VOLTAGE (Volt)? (e.g. 30.0)' READ (9,21) E IF (E.EQ.0.) E=30.

WRITE (9,11)'CURRENT (Amp)? (e.g. 250.)' READ (9,21) EI IF (EI.EQ.0.) EI=250. WRITE (9,11)'HEAT TRANSFER EFFICIENCY? (e.g. 0.9)' READ (9,21) F1 IF (F1.EQ.0.) Fl=.9 WRITE (9,11)'MELTING EFFICIENCY? (e.g. 1.0)' READ (9,21) F2 IF (F2.EQ.0.) F2=1. Q=F1*F2*E*EI 609 WRITE (9,11)'WELDING SPEED (mm/s)? (e.g. 6.0)' READ (9, 21) V IF (V.EQ.0.) V=6. WRITE (9,11)'THERMAL CONDUCTIVITY (J/s.mm.C)? ( e.g. 0.025)' READ (9,21) THK IF (THK.EQ.0.) THK=.025 WRITE (9,11)'WELD DENSITY (kg/m^3)? (e.g. 7000.0)' READ (9,22) THO IF (THO.EQ.0.) THO=7000. THO=THO/1000000000. T=2. *PI*THK*THO*C*V* (TM-TA) **2 TIME=HL*Q/T WRITE (9,690) TIME 690 FORMAT (/'SOLIDIFICATION TIME =', F7.3,' (sec)' ) PAUSE GO TO 1 C —----------------------— NO.7 —---- 700 WRITE (9,11)'ENTER DIMENSION? (2=THIN PLATE, 3=THICK PLATE)' READ (9,702) I 702 FORMAT (I1) IF (I.EQ.0) I=2 WRITE (9,11)'MELTING TEMPERATURE (C)? (e.g. 1500.0)' READ (9,21) TM IF (TM.EQ.0.) TM=1500. WRITE (9,11)'THERMAL CONDUCTIVITY (J/s.mm.C)? ( e.g. 0.05)' READ (9,21) THK IF (THK.EQ.0.) THK=.05 WRITE (9,11)'WELD DENSITY (kg/m^3)? (e.g. 8000.0)' READ (9,22) THO IF (THO.EQ.0.) THO=8000.

THO=THO/1000000000. WRITE (9,11)'SPECIFIC HEAT (kj/kg.K)? (e.g. 0.850)' READ (9,21) C IF (C.EQ.0.) C=.85 C=C*1000. ALPHA=THK/(THO*C) WRITE (9,11)'WELDING SPEED (mm/s)? (e.g. 10.0)' READ (9, 21) V IF (V.EQ.0.) V=10. WRITE (9,11)'HEAT INPUT (j/s)? (e.g. 6000.0)' READ (9,22) Q IF (Q.EQ.0.) Q=6000. IF (I.NE.3) GO TO 760 C —-------------— 3-D CB=1. 6*ALPHA/V CC=4.*ALPHA*Q/(1.25*PI*THK*TM*V) W=. 5* (-CB+ (CB**2. +4.*CC) **.5) WRITE (9,750) W 750 FORMAT (/'BEAD WIDTH =' F10.3,' (mm)') PAUSE GO TO 1 760 IF (I.NE.2) GO TO 1 C- --— 2-D WRITE (9,11)'THICKNESS (mm) =? (e.g. 10.0) READ (9,21) H IF (H.EQ.0.) H=10. W=(4.*ALPHA/V) * (Q/(8.*THK*H*TM)-.2) WRITE (9,790) W 790 FORMAT (/'BEAD WIDTH =' F10.3,' (mm)') PAUSE GO TO 1 C —------------------------ NO.8 -------------------------------- 800 WRITE (9,805) 805 FORMAT ('*************************************************'//;' ARRANGEMENT OF STRAIN GAUGES'/;' 1) DELTA OR STAR ROSETTE /;' 2) RECTANGULAR ROSETTE / _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

;' O0) MAIN MENU /' ENTER NUMBER?'/) READ (9,30) II IF (II.EQ.0) GO TO 1 WRITE (9,11)'ELASTIC MODULUS (GPa)? (e.g. 200.) READ (9,22) E IF (E.EQ.0.) E=200. WRITE (9,11)'POISSON RATIO? (e.g. 0.3) READ (9,21) V IF (V.EQ.0.) V=.3 IF (II.NE.1) GO TO 830 C —-------------------------------— DELTA ROSETTE WRITE(9,11)'MEASURED STRAIN (0-DEGREE-GAGE)? (e.g. 0.000750)' READ (9,810) EA 810 FORMAT (F8.6) IF (EA.EQ.0.) EA=.000750 WRITE(9,11)'MEASURED STRAIN (120-DEGREE-GAGE)? (e.g.0.000283)' READ (9,810) EB IF (EB.EQ.0.) EB=.000283 WRITE(9,11)'MEASURED STRAIN (240-DEGREE-GAGE)? (e.g.0.000500)' READ (9,810) EC IF (EC.EQ.0.) EC=.000500 EX=EA EY=(2.* (EB+EC) -EA)/3. EXY=2.* (EC-EB)/1.732 GO TO 840 C —------------------------------— RECTANGULAR ROSETTE 830 WRITE(9,11)'MEASURED STRAIN (0-DEGREE-GAGE)? (e.g. 0.000750)' READ (9,810) EA IF (EA.EQ.0.) EA=.000750 WRITE(9,11)'MEASURED STRAIN (45-DEGREE-GAGE)? (e.g.0.000283)' READ (9,810) EB IF (EB.EQ.0.) EB=.000283 WRITE(9,11)'MEASURED STRAIN (90-DEGREE-GAGE)? (e.g.0.000500)' READ (9,810) EC IF (EC.EQ.0.) EC=.000500 EX=EA EY=EC EXY=2. *EB-EA-EC

C —----- ------------— CALCULATE PRINCIPAL STRAIN 840 El=(EX+EY)/2. + SQRT(((EX-EY)/2.)**2+EXY**2) E2=(EX+EY)/2. - SQRT(((EX-EY)/2.)**2+EXY**2) C —-----------------------— CALCULATE PRINCIPAL STRESS Sl=-E/(1.-V**2) * (El+V*E2) *1000. S2=-E/(1.-V**2) * (E2+V*E2)*1000. TAU=(S1-S2)/2. WRITE (9,890) S1, S2,TAU 890 FORMAT (/'PRINCIPAL RESIDUAL STRESS 1:',F8.2,' (MPa)', /'PRINCIPAL RESIDUAL STRESS 2:',F8.2,' (MPa)', /'MAXIMAL SHEAR STRESS:',F8.2,' (MPa)' ) PAUSE GO TO 800 C —----------------------— NO.9 —------------------------------------- 900 WRITE (9,905) 905 FORMAT ('*************************************************'// WELD DISTORTION MENU'/ I; -,~/ 1) TRANSVERSE SHRINKAGE'/' 2) LONGITUDINAL SHRINKAGE'/ 3) ANGULAR DISTORTION 0) MAIN MENU'/' ENTER NUMBER?'/) READ (9,30) II IF (II.EQ.0) GO TO 1 GO TO (910,950,970) II C —------------------------------------ - 1) TRANSVERSE SHRINKAGE 910 WRITE (9, 915) 915 FORMAT ('************************************************* //;' TRANSVERSE SHRINKAGE MENU'/ / —------------------------------------- 1) BUTT WELDS'/'2) FILLET WELDS'/' O) WELD DISTORTION MENU' /'ENTER NUMBER?'/)

READ (9, 30) III IF (III.EQ.0) GO TO 900 GO TO (920,940) III C —---------------------------- 1) BUTT WELDS 920 WRITE (9,11)'SINGLE OR MULTIPASS? 1=SINGLE, 2=MULTIPASS' READ (9,30) J IF (J.NE.1) GO TO 930 C —------------ SINGLE PASS WRITE (9,11)'WELD CROSSECTIONAL AREA (in^2)? (e.g. 0.207)' READ (9,21) A IF (A.EQ.0.) A=.207 WRITE (9,11)'THICKNESS (in)? (e.g. 0.5)' READ (9,21) H IF (H.EQ.0.) H=.5 WRITE (9,11)'ROOT OPENING (in)? (e.g. 0.125)' READ (9,21) D IF (D.EQ.0.) D=.125 S=.2*A/H +.05*D WRITE (9,925) S 925 FORMAT (/'SHRINKAGE =',F8.4,' (in)') PAUSE GO TO 910 C —------------------- MULTIPASS 930 WRITE (9,11)'FIRST PASS SHRINKAGE (in)? (e.g. 0.111)' READ (9,21) SO IF (S0.EQ.0.) S0=.111 WRITE (9,11)'WELD WEIGNT IN lst-PASS (lb/in)? (e.g.0.035)' READ (9,21) WO IF (WO.EQ.0.) WO=.035 WRITE (9,11)'ACCUMULATED WELD WEIGNT (lb/in)? (e.g.0.065)' READ (9,21) W IF (W.EQ.0.) W=.065 S=SO +.37*ALOG(W/WO) WRITE (9,935) S 935 FORMAT (/'TOTAL SHRINKAGE =',F8.4,' (in)') PAUSE GO TO 910 C —------ 2) FILLET WELDS 940 WRITE (9,11)'LAP OR T-JOINT? (1=LAP, 2=T-JOINT) READ (9,30) ILT

IF (ILT.EQ.0) ILT=1 ALPHA=. 06 IF (ILT.EQ.2) ALPHA=.04 WRITE (9,11)'PLATE THICKNESS (in)? (e.g. 0.75)' READ (9,21) H IF (H.EQ.0.) H=.75 WRITE (9,11)'LEG OF FILLET (in)? (e.g. 0.5)' READ (9,21) FL IF (FL.EQ.0.) FL=.5 S=FL/H*ALPHA WRITE (9,945) S 945 FORMAT (/'SHRINKAGE =',F6.3,' (in)') PAUSE GO TO 910 C —------------------------------------- 2) LONGITUDINAL SHRINKAGE 950 WRITE (9,11)'CURRENT (amp)? (e.g. 300.)' READ (9,21) CI IF (CI.EQ.0.) CI=300. WRITE (9,11)'PLATE THICKNESS (in)? (e.g. 0.75)' READ (9,21) H IF (H.EQ.0.) H=.75 WRITE (9,11)'WELD LENGTH (in)? (e.g. 20.0)' READ (9,21) WL IF (WL.EQ.0.) WL=20. S=. 12*CI*WL/(100000. *H) WRITE (9,955) S 955 FORMAT (/'SHRINKAGE =',F6.3,' (in)') PAUSE GO TO 900 C —------------------------------------- 3) ANGULAR DISTORTION 970 WRITE (9,11)'ELASTIC MODULUS (GPa)? (e.g. 206.) READ (9,22) E IF (E.EQ.0.) E=200. E=E/9.81*1000. WRITE (9,11)'POISSON RATIO? (e.g. 0.3) READ (9,21) V IF (V.EQ.0.) V=.3 WRITE (9,11)'LENGH OF SPAN (mm)? (e.g. 750.)' READ (9,21) SL

IF (SL.EQ.0.) SL=750. WRITE (9,11)'DISTANCE FROM JOINT (mm)? (e.g. 375.)' READ (9,21) X IF (X.EQ.0.) X=375. WRITE (9,11)'PLATE THICKNESS (mm)? (e.g. 19.)' READ (9,21) H IF (H.EQ.0.) H=19. WRITE (9,11)'WELD WEIGHT (g/cm)? (e.g. 3.925)' READ (9,21) W IF (W.EQ.0.) W=3.925 WRITE(9,11)'ANGULAR CHANGE IN A FREE JOINT (rad)? (e.g.0.016)' READ (9,21) PHI0 IF (PHI.EQ.0.) PHIO=.016 C=H**4/(1.+0.2*W) D=E*H**3/(12.* (1-V**2)) PHI=PHI0/(1. +2*D/(SL*C)) DELTA=PHI*SL* (.25-(X/SL-.5)**2) WRITE (9,975) DELTA 975 FORMAT ('DISTORTION =',F6.3,' (mm)') PAUSE GO TO 900 C —----------------------------— NO.10 —----------------------------- 1000 WRITE (9,1015) 1015 FORMAT ('*************************************************I//;' WELDMENT DESIGN MENU'/; -------------------------------------— /' 1) BUTT WELDS'/' 2) FILLET WELDS'/ ~ /; 0 O) MAIN MENU'/' ENTER NUMBER?'/) READ (9,30) II IF (II.EQ.0) GO TO 1 GO TO (1020,1040) II C —-------- ------------------ 1) BUTT WELDS 1020 WRITE (9,11)'APPLIED LOAD (lb)? (e.g. 40000.)' READ (9,1025) P 1025 FORMAT (F9.2) IF (P.EQ.0.) P=40000.

WRITE (9,11)'PLATE THICKNESS (in)? (e.g. 0.4)' READ (9,21) H IF (H.EQ.0.) H=.4 WRITE (9,11)'WELD LENGTH (in)? (e.g. 20.0)' READ (9,21) WL IF (WL.EQ.0.) WL=20. STRESS=P/ (H*WL) WRITE (9,1030) STRESS 1030 FORMAT (/'STRESS IN WELD =',F10.2,' (psi)') PAUSE GO TO 1000 C —-------------------- 2) FILLET WELD 1040 WRITE (9,1045) 1045 FORMAT (/'******************************************** FILLET WELDS DESIGN MENU; ---------------------------------------; 1) TENSION TEST;2) TORSION TEST 3) BENDING TEST ~;............. —0) WELD DESIGN MENU; ENTER NUMBER? READ (9,30) II IF (II.EQ.0) GO TO 1000 GO TO (1050,1070,1090) II C —-------------------------- 1) TENSION TEST 1050 WRITE (9,11)'APPLIED LOAD (lb)? (e.g. 40000.)' READ (9,1055) P 1055 FORMAT (F9.2) IF (P.EQ.0.) P=40000. WRITE (9,11)'PLATE THICKNESS (in)? (e.g. 0.4)' READ (9,21) H IF (H.EQ.0.) H=.4 WRITE (9,11)'WELD LENGTH (in)? (e.g. 20.0)' READ (9,21) WL IF (WL. EQ.0.) WL=20. STRESS=P/(.707*H*WL) WRITE (9,1060) STRESS

1060 FORMAT (/'SHEAR STRESS IN WELD =',F10.2,' (psi)') PAUSE GO TO 1040 C —-----------------------— 2) TORSION TEST 1070 WRITE (9,11)'TORQUE (lb-in)? (e.g. 35900.)' READ (9,1075) T 1075 FORMAT (F9.2) IF (T.EQ.0.) T=35900. WRITE (9,1080) 1080 FORMAT (/'UNIT POLAR MOMENT OF INERTIA OF WELD GROUP','ABOUT CENTROID (in^3)? (e.g. 20.833)' ) READ (9,21) PJU IF (PJU.EQ.0.) PJU=20.833 WRITE (9,11)'WELD LEG (in)? (e.g. 0.25)' READ (9,21) H IF (H.EQ.0.) H=.25 WRITE (9,11)'DISTANCE FROM CENTROID (in)? (e.g. 2.15)' READ (9,21) R IF (R.EQ.0.) R=2.15 PJ=.707*H*PJU TAU=T*R/PJ WRITE (9,1085) TAU 1085 FORMAT (/'SHEAR STRESS DUE TO TORSION =',F8.2,' (psi)') PAUSE GO TO 1040 C —------------------------- 3) BENDING TEST 1090 WRITE (9,11)'BEAM LENGTH (in)? (e.g. 15.0)' READ (9,21) A IF (A.EQ.0.) A=15. WRITE (9,11)'BEAM THICKNESS (in)? (e.g. 1.)' READ (9,21) D IF (D.EQ.0.) D=1. WRITE (9,11)'BEAM WIDTH (in)? (e.g. 10.)' READ (9,21) B IF (B.EQ.0.) B=10. WRITE (9,11)'WELD LEG (in)? (e.g. 0.4)' READ (9,21) H IF (H.EQ.0.) H=.4 WRITE (9,11)'APPLIED LOAD (lb)? (e.g. 2000.)'

READ (9,1095) P 1095 FORMAT (F9.2) IF (P.EQ.0.) P=2000. SX=P*A*(D/2.+H)/(.707*H*B*D**2/2.) SY=O. SXY=P/(.707*H*B*2) S1=(SX+SY)/2. + SQRT(((SX-SY)/2.)**2+SXY**2) S2=(SX+SY)/2. - SQRT(((SX-SY)/2.)**2+SXY**2) WRITE (9,1100) S1,S2 1100 FORMAT (/'PRINCIPAL STRESSES =',F11.2,' AND',F11.2,'(psi)') GO TO 1040 C —----------------------- END —-------------------------------------- 9999 END

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