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International INTERNATIONAL Journal of Mechanical JOURNAL Engineering OF and MECHANICAL Technology (IJMET), ISSN ENGINEERING 
0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
AND TECHNOLOGY (IJMET) 
ISSN 0976 – 6340 (Print) 
ISSN 0976 – 6359 (Online) 
Volume 5, Issue 8, August (2014), pp. 07-19 
© IAEME: www.iaeme.com/IJMET.asp 
Journal Impact Factor (2014): 7.5377 (Calculated by GISI) 
www.jifactor.com 
IJMET 
© I A E M E 
RESEARCH ON THE INFLUENCE OF SAGGING AND CONTINUOUS 
UNDERCUT ON THE CAPACITY OF BUTT-WELDED JOINT 
Vladimir Stojmanovski1, Zoran Bogatinoski2, Viktor Stojmanovski3 
1(Centre for Research, Development and Continuous Education – CIRKO, Inspection Body for 
Pressure Vessels, Metal Structures and Cableways, Skopje, Macedonia) 
2(Professor, Ss. Cyril and Methodius University in Skopje, Faculty of Mechanical Engineering, 
Skopje, Macedonia) 
3(Associate Professor, Ss. Cyril and Methodius University in Skopje, Faculty of Mechanical 
Engineering, Skopje, Macedonia) 
7 
ABSTRACT 
The behavior of butt-welded joint with imperfection of the outer contour due to sagging and 
continuous undercut has been analyzed in this paper. The analysis was done by testing and numerical 
investigation using Finite Element Analysis. 
For the testing, the standard probes have been made from material S235JR that is mostly used 
for the production of welded structures. Sagging and continuous undercut on both sides of the testing 
plates have been simulated in the welded joint in order to evaluate the imperfection. 
Research presented in this paper is directed in gaining acknowledgement and experience for 
analysis of the welded structures and their usage in design, construction, production and testing. In 
that manner the real picture of stress distribution is going to be acquired and this will contribute in 
the design of structures with decreased factor of safety leading to less expensive and yet safe 
structures which is the common interest of the companies that construct, produce and assemble 
welded structures. 
The purpose of this paper is to endorse the influence of the sagging and continuous undercut 
on the capacity of the welded joint in order to make appropriate judgment for the safety. 
Keywords: Butt-Weld, Continuous Undercut, FEA, Imperfection, Material Testing, Sagging. 
I. INTRODUCTION 
Due to discontinuities from various imperfections found on the outer contour of the welded 
joint (such as sagging and continuous undercut), there is irregular stress distribution at the joint with
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
elevated stress peaks. The influence of these peaks cannot be precisely estimated during the 
calculation of the joint. In practice, the solution of the problem, in order to prevent the existence of 
such imperfections, lays in establishment of rigorous criteria prescribed by the regulation. 
Sometimes there is a question whether these rigorous criteria are reasonable due to the fact that they 
directly influent the costs of the welded structure. On the other side, in some separate cases as far as 
there is discontinuity, it is very likely that during the reparation the situation might worsen, 
particularly if there is a location where the reparation is hard to be made. Considering these facts, in 
some cases, it is necessary to make judgment whether there is need to make reparation on the 
discontinuities found on the outer contour during the examination. 
In this paper has been analyzed the behavior of butt-welded joint with imperfection of the 
outer contour due to sagging and continuous undercut. 
The probes used for the tensile, bending and toughness tests are standard and they are 
produced from the plates [2] made from material S235JR that is mostly used for the production of 
welded structures. Chemical composition and mechanical properties have been obtained by 
analyzing the material. Appropriate welding technology for the probes has been adopted according to 
EN499 and E7018 according to AWSA 5.2. the technology has been verified and appropriate WPQR 
certificate has been issued. 
Sagging and continuous undercut on both sides of the testing plates (probes) were simulated 
at the welded joint. Static examination of the basic material S235JR and the welded joint are made. 
The joints are analyzed by FEA in their real dimensions of the model and the imperfections with the 
ALGOR software [4]. Such analysis has shown the stress distribution of the joint. 
Research presented in this paper is directed in gaining acknowledgements and experience for 
analysis of the welded structures and their usage in design, construction, production and testing. In 
that manner is going to be acquired the real picture of stress distribution that will contribute in the 
design of structures with decreased factor of safety leading to less expensive and yet safe structures 
that are the common interest of the companies which project, produce and assemble welded 
structures. 
8 
II. BASIC MATERIAL 
Models (probes) analyzed in this paper are produced from material S235JR. The material has 
been tested in the laboratory and properties of material gained from the test are presented in Table 1 
and Table 2. 
Table 1: Chemical Composition of the material 
Chemical element (%) 
C Si Mn P S Cr Ni Al Cu Nb Ti Mo V B Cekv 
0,11 0,08 0,58 0,013 0,012 0,03 0,02 0,043 0,03 0,02 0,01 0,01 0,01 0,0 0,213 
Table 2: Mechanical Properties of the material 
Dimensions 
Fm 
(N) 
Tension Bending Toughness 
Reh 
(Mpa) 
Rm 
(MPa) 
A5 
(%) 
Reh/Rm 
 
(mm) 
 
(0) 
 
(J) 
9,5x24,6 L=118 L0=90 120980 366 517 31,5 0,71 Ø40 180 
112 
t= + 200C
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 0 
Tension test graph is presented on Figure 1. 
07-19 © IAEME 
Fig. 1: Tension test graph for material S235JR 
From the performed tests, it can be concluded that chemical composit 
properties, the elongation, bending and toughness meet the requirements of the standard EN 10025 
for the quality of the material S235JR. 
III. WELDING TECHNOLOGY 
Welding of the plates was performed with TIG welding procedure (141) for the root 
ARC welding procedure for filling and finish. ARC welding was performed with basic electrode type 
E424 32 X5 according to EN499 and E7018 according to AWSA 5.2 [3]. 
Fig. 2: Welding order: 1. Root 
-TIG (141), 2. Filling -ARC (111), 3. Finish - 
Professionally qualified welder who possesses valid certificates performed the welding. The 
prescribed welding technology was verified and the WPQR certificate has been issued 
IV. THE PROBES FOR THE TESTING 
From the Basic material using the presc 
prescribed welding technology appropriate plates are 
created for the purpose of the test. The characteristic imperfections (sagging and continuous 
9 
– 6340(Print), 
composition, mechanical 
weld and 
ARC (111) 
ribed
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
undercut) are simulated at the joint. The imperfection models used in the further tests are presented 
in Table 3 
Table 3: The Models (probes) used for the tests 
10 
Probe mark 
1. Welded joint with grinded face and root 
2.1 
2. Weld with significant sagging on one side 
2.6. 
3. Weld with continuous undercut on both sides 
2.7. 
IV.1. PERMITTED DEVIATION OF THE IMPERFECTIONS 
The characteristic imperfections according to ISO 6520, depending on the level of quality of 
the weld are presented in Table 4. 
Table 4: Permitted deviation of the imperfections according to ISO 6520 
Appearance of the 
imperfection 
t (mm) 
Boundary values of the imperfection for the level of quality 
D C B 
2.6. 
 3 
Small sizes 
h0,25 t 
no max 2 mm 
for probe 2.6 
h2,375 mm 
Small sizes 
h0,1 t 
no max 1 mm 
for probe 2.6 
h0,95 mm 
Small sizes 
h0,05 t 
no max 0,5 mm 
for probe 2.6 
h0,475 mm 
2.7. 
 3 
h0,2 t 
no max 1 mm 
for probe 2.7 
h1,9 mm 
h0,1 t 
no max 0,5 mm 
for probe 2.7 
h0,95 mm 
h0,05 t 
no max 0,5 mm 
for probe 2.7 
h0,475 mm 
IV.2. VISUAL EXAMINATION OF THE WELDED JOINTS 
Visual examination and dimensional control of the welded joints are performed in order to 
evaluate the imperfections. The results from the dimensional control of the imperfections are 
presented in Table 5. 
Table 5: Results from the dimensional control 
Joint with significant sagging 
2.6. 
a1 
(mm) 
b1 
(mm) 
a 
(mm) 
b 
(mm) 
c 
(mm) 
7,6 2 14 1 1 
Joint with continuous undercut 
2.7. 
a1 
(mm) 
b1 
(mm) 
a 
(mm) 
b 
(mm) 
c 
(mm) 
c1 
(mm) 
6,4 2 16,4 2 2 2 
t 
h 
t 
h
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
IV.3. RADIOGRAPHIC CONTROL OF THE JOINTS 
Welded probes – plates are radiography tested. The radiograms are presented in Table 6 
Table 6: Radiograms 
Welded joint with grinded surfaces 
Mark Model Radiogram 
11 
2.1. 
Grinded face and 
grinded root 
2.6. 
Significant sagging 
2.7. 
Continuous undercut 
The defects are clearly recognizable on the radiogram. 
V. TESTING OF THE WELDED JOINTS 
Tensile, bending and toughness tests are performed in order to examine the effect of the 
imperfection 
V.1 TENSILE TEST 
The tensile test was performed on both the basic material and the samples without (2.1) and 
with imperfections (2.6 and 2.7). The tensile test graph for the basic material is presented on figure 2. 
The results from the tensile tests for the models 2.1, 2.6 and 2.7 and for the basic material marked 
with 2. are presented in Table 7. 
Table 7: The results from the tensile test 
Test 
probe 
Probe 
dimension 
A0 
(mm2) 
Rp0,2 
(N/mm2) 
Breaking 
force 
Fm(N) 
Rupture 
stress 
Rm (N/mm2) 
Location of rupture 
2. 9,5 x 24,6 233,70 366 120980 517 5=31,5% 
2.1 9,2 x 24,2 220,80 386 123290 558 Basic material 
2.6 8,8 x 24,2 212,96 393 126580 594 Basic material 
Zone of the 
2.7 8,8 x 24,5 215,60 355 119520 554 
temperature influence
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
All of the welded plates have equal nominal thickness. Therefore, at the location of the joint, 
the widths of the probes are approximately equal. The cross sectional area at the location of the 
rupture changes due to the different size (depth of the imperfection). At the welded structures where 
the joints are butt-welded the area of the cross-section has to be constant. For the calculation of the 
butt-welded joint according to the existing standards, the thickness of the weld is permanently 
considered as equal to the thickness of the basic material. Then, for different nominal cross section, 
for defining of the capacity, for comparison most relevant element is the breaking force Fm (N) 
acquired from the test. The intensity of the breaking force is presented on Figure 3. 
Fig. 3: The breaking force Fm(N) 
12 
V.2 BENDING TEST 
The results from the bending test of the basic material (signed with 2.), the welded joint with 
no imperfection (signed with 2.1) and welded joints with appropriate imperfections (signed with 2.6 
and 2.7) are presented in Table 8 
Table 8: Results from the bending test 
Test 
probe 
Type of 
test 
Dimension 
(mm) 
Diameter of 
bend former 
(mm) 
Shoulders 
distance 
(mm) 
Bending angle 
(0) 
2. RBB/FBB 10x30 Ø40 70 180 
2.1 RBB/FBB 10x30 Ø40 70 180 / 180 
2.6 RBB/FBB 10x30 Ø40 70 180 / 180 
2.7 RBB/FBB 10x30 Ø40 70 180 / 180 
V.3. TOUGHNESS TEST 
The results from the toughness test of the basic material (signed with 2.), the welded joint 
with no imperfection (signed with 2.1) and welded joints with appropriate imperfections (signed with 
2.6 and 2.7) are presented in Table 9. The test was performed according to EN875
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
Table 9: Results from the toughness test 
13 
Probe mark 
Dimension 
of the probe 
a x10 x 55 
Temperature 
(0C) 
A0 
(cm2) 
Deformation energy 
(J) 
Calculated toughness 
(J/cm2) 
Location 
of the 
groove 
Type 
of 
1 2 3 Sr. 1 2 3 Sr. groove 
2. V 9,2x10x55 +20 0,74 78 138 120 112 105 187 163 151 
Middle 
of the 
weld 
V 
2.1 V 9,2x10x55 +20 0,736 144 104 90 112 195 141 122 152 
Middle 
of the 
weld 
V 
2.6 V 11,0x10x55 +20 0,88 191 294 207 230 217 334 235 262 
Middle 
of the 
weld 
V 
2.7 V 12,5x10x55 +20 1,0 262 294 295 283 262 294 295 283 
Middle 
of the 
weld 
V 
According to the analysis of the results of the toughness test it can be concluded: 
- Obtained values of the toughness material meet the requirements for the toughness of the 
material S235JR at the temperature of +200C. Minimum required is 27 J 
- Since the groove of the probe is located in the middle of the joint, discontinuities 2.1, 2.6 and 
2.7 do not influence the toughness. 
VI. FINITE ELEMENT ANALYSIS OF THE IMPERFECTIONS 
Plane strain models for the analysis of the considered cases were used. The analysis was 
performed with ALGOR software. The models are loaded with Fsr=65KN, force that delivers stress 
condition close to the yielding. 
The Yield stress measured from the tensile test is used as load criteria in the Finite Element 
Model. For the material S235JR the load is Rp=366 N/mm. According to EN 10025, the material has 
minimum yield stress Reh=235 N/mm2. In such case the proper value is the one measured from the 
tensile test Rp(0,2)=366 N/mm2. The Young modulus for all the analyzed cases is 2,1x105 N/mm2. In 
the Finite Element Model, at the locations of the imperfections the finer mesh has been used. [4]. 
VI.1. STRESS DISTRIBUTION DUE TO THE IMPERFECTIONS 
VI.1.1. WELDED PLATE WITHOUT IMPERFECTIONS (GRINDED FACE AND ROOT – 
MODEL 2.1) 
The real model and the Finite Element Model are presented on Figure 4. 
Fig. 4: The real model and the Finite Element Model for the case 2.1
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 0 
The stress distribution is presented on Figure 5 
07-19 © IAEME 
Fig. 5: The stress distribution for the case 2.1 (no imperfection) 
VI.1.2. WELDED PLATE WITH SAGGING (MODEL 2.6) 
The real model and the Finite Element Model are presented on Fi 
Fig. 6: The real model and the Finite Element Model for the case 2.6 
14 
Figure 6. 
– 6340(Print),
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
15 
The stress distribution is presented on Figure 7 
Fig. 7: The stress distribution for the case 2.6 (sagging) 
VI.1.3. WELDED PLATE WITH CONTINOUS UNDERCUT (MODEL 2.7) 
The real model and the Finite Element Model are presented on Figure 8. 
Fig. 8. The real model and the Finite Element Model for the case 2.7
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
16 
The stress distribution is presented on Figure 9 
Fig. 9: The stress distribution for the case 2.7 (continuous undercut) 
VI.2. ANALYSIS OF THE RESULTS FROM THE FEA 
Stress distribution at the welded joint for different cases (models) is presented on Figures 5, 7 
and 9. At sufficient distance from the welded joint there is steady stress condition. If the stress 
distribution is analyzed, it may be concluded that at the locations where the continuity is interrupted 
(imperfection) there is existence of the stress peak. These peaks are close to the values of the yield 
stress of the basic material. Analyzing the results of the FEA, the following may be summarized: 
- The Imperfections (defects) have significant influence on the stress distribution, 
- When the model is loaded with the force Fsr, near the defects (discontinuities), the stress 
achieves the values close or equal to the yield stress of the material, 
- The verification of the proper modeling is the fact that far enough from the weld there is 
steady stress that in fact is the stress delivered when the force Fsr is divided by the cross-sectional 
area of the plate (the probe). 
VII. COMPARATIVE ANALYSIS AND THE REVIEW OF THE RESULTS 
The results from the tensile test of the basic material S235JR and the welded plates with 
various imperfections are presented in table 7. For defining of the capacity of the joint the most 
proper element for comparison is the value of the breaking force Fm. The value of the breaking force 
graphically is presented in Figure 30. The Material S235JR is characterized by good strength 
properties and good weldability. 
The results from the tensile test are: 
- Yielding stress Rp0,2=366 N/mm2, 
- Rupture stress Rm=517 N/mm2, 
- Breaking elongation 5=31,5%. 
According to the provided strength and deformation properties and the chemical composition 
it can be concluded that the material S235JR for the butt-welded profiles (2.1, 2.6 and 2.7), 
completely fulfills the requirements of the standard EN 10025.
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
The breaking force from the tensile test of the joint with grinded face and root (2.1) is 
17 
Fm 
(2.1)=123290 N. This force is approximately equal with the breaking force of the basic material 
Fmom.=120890 N. The variation is within the tolerant limits. The rupture occurred in the basic 
material. 
From the bending test of the probe 2.1 has been obtained bending angle of 1800. It means that 
in both cases the criteria of the used bending test standard has been fulfilled. 
The results from the toughness test of the probe 2.1 are presented in the table 14. The measured 
values for the toughness fulfill the requirements for the material S235JR at the temperature of +200C. 
Minimum required value is 27J 
Permitted depth of the sagging depending on the level of quality is presented in Table 10 and 
the measured dimensions of the weld with sagging are presented in Table 11. 
Table 10: Permitted values of the sagging 
Level of quality 
D C B 
Depth of the sagging h (mm) 2,375 0,95 0,475 
Depth of the sagging h (mm) - maximum allowed 2,00 1,00 0,50 
Table 11: Measured dimensions of the sagging 
Probe Depth of the sagging h (mm) 
2.6 1,00 
From the visual examination and dimension control can be concluded that welded probe 2.6 
does not fulfill the criteria for the level of quality C and B. 
From the tensile test of the welded probe 2.6, the measured breaking force is Fm 
(2.6)=126580 
N. By comparing the results from the basic material (probe 2.) and the weld without imperfections 
(grinded face and root - probe 2.1) can be summarized: 
- The breaking force Fm 
(2.6) is superior than breaking forces of the basic material and the probe 
2.1 
- The rupture occurred at the basic material 
- The stress concentration due to imperfection of the outer contour (Figure 7) does not 
influence the capacity of the joint in the static loading condition. This is due to superior 
ductility of the material S235JR. 
From the bending test of the probe 2.6 (Table 8) the bending angle of 1800 has been 
measured. It proves that in both cases the required criteria from the bending test standard has been 
fulfilled. 
From the toughness test of the probe 2.6, (Table 9) have been measured toughness values that 
fulfill the requirements of the toughness of the material S235JR on +200C (probes 2.6) 
Permitted depth of the continuous undercut depending on the level of quality is presented in 
Table 12 and the measured dimensions of the excess metal are presented in Table 13. 
Table 12: Permitted values of the continuous undercut 
Level of quality 
D C B 
Depth of the root h (mm) 1,90 0,95 0,475 
Depth of the root h (mm) - maximum allowed 1,00 0,50 0,50
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
Table 13: Measured dimensions 
Probe Depth of the root h (mm) 
2.7 2,00 
From the visual examination and dimension control can be concluded that welded probe 2.7 
does not fulfill the criteria for the level of quality D, C and B. 
From the tensile test of the welded probe 2.7, the measured breaking force is Fm 
(2.7) is superior than capacity of the probe 2.1. This 
18 
(2.7)=119540 
N. By comparing the results from the basic material (probe 2.) and the weld without imperfections 
(grinded face and root - probe 2.1) can be summarized: 
- The cross sectional area of the probe 2. is A0 
(2)=233,70mm2, and of the probe 2.7 is 
A0 
(2.7)=215,60mm2. It gives A0 
(2.7)=0,92A0 
(2). After performing the reduction Fm 
(2.7)=130000 
N. Reduced capacity of the probe 2.7, Fm 
proved that the decreasing of the carrying capacity of the model 2.7 Fm 
(2.7)=119520 N is result 
of decreased cross-sectional area due to the continuous undercut. 
- The rupture occurred in the zone of the thermal influence. This is result of the location of the 
zone of thermal influence where by undercut the cross-section is decreased. 
- The stress concentration due to discontinuity of the outer contour (Figure 9) does not 
influence the capacity of the welded joint in the condition of static loading. 
From the bending test of the probe 2.7 and both the root in compressed zone and the root in 
tension zone the requirements for the bending tests are fulfilled. In both cases the bending angle of 
1800 has been achieved. 
From the toughness test of the probes 2.7 (table 12) are obtained values for toughness that 
meet the requirements for the toughness of the material S235JR at +200C. (Probe 2.7) 
VIII. CONCLUSIONS 
From the FEA, the experiments and the analysis of the results from the research it may be concluded: 
• The material S235JR of the probes with butt-welds (2.1, 2.6 and 2.7) completely fulfills the 
requirements of the standard EN10025. The material has good weldability and due to 
increased ductility is less sensitive to the stress concentration. 
• Superior sagging (probe 2.6) depending on the depth can influence the capacity of the joint in 
static (and presumably in dynamic conditions). The depth of the sagging fulfills the permitted 
value for class of quality D (h=1 mm  2mm), but does not fulfill the permitted limits for the 
class B (h=1mm  0,5 mm) and h=1 mm = 1mm (class C). 
• The high continuous undercut (probe 2.7) depending on the depth has influence of the weld 
capacity. The depth of the weld with continuous undercut is higher than the permitted value 
for D, C and B level of quality. 
• In the static loading conditions, during the quality assessment of the welded joints in the 
aspect of imperfections that cause discontinuity of the outer contour can be allowed certain 
violation of the imperfection dimensions compared to the permitted values of the standard 
ISO 6520. 
• During the quality assessment of the welded joints it should be considered the level of stress 
at the weld, the kind of the stress and the kind of the loading of the structure. 
• During the quality assessment of the welded joints, particularly the dynamically loaded 
joints, the material of the welded structure must be considered. That is due to the fact that 
different materials have different sensibility of the stress concentration.
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), 
ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 
• Having in mind the knowledge gained from this paper, in certain cases the certain welds may 
be judged positive even when there are present some imperfections, particularly 
imperfections in the outer contour. For delivering such judgment, the person must have good 
understanding of materials, welding, construction, design, calculation etc. 
19 
REFERENCES 
[1] Werner Mewes; Kleine Schweibkunde fur Maschinenbauer, 2 Auflage, VDI-Verlag GmbH, 
Du basic material Dusseldorf 1992. 
[2]

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Research on the influence of sagging and continuous undercut on the capacity

  • 1. International INTERNATIONAL Journal of Mechanical JOURNAL Engineering OF and MECHANICAL Technology (IJMET), ISSN ENGINEERING 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME AND TECHNOLOGY (IJMET) ISSN 0976 – 6340 (Print) ISSN 0976 – 6359 (Online) Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME: www.iaeme.com/IJMET.asp Journal Impact Factor (2014): 7.5377 (Calculated by GISI) www.jifactor.com IJMET © I A E M E RESEARCH ON THE INFLUENCE OF SAGGING AND CONTINUOUS UNDERCUT ON THE CAPACITY OF BUTT-WELDED JOINT Vladimir Stojmanovski1, Zoran Bogatinoski2, Viktor Stojmanovski3 1(Centre for Research, Development and Continuous Education – CIRKO, Inspection Body for Pressure Vessels, Metal Structures and Cableways, Skopje, Macedonia) 2(Professor, Ss. Cyril and Methodius University in Skopje, Faculty of Mechanical Engineering, Skopje, Macedonia) 3(Associate Professor, Ss. Cyril and Methodius University in Skopje, Faculty of Mechanical Engineering, Skopje, Macedonia) 7 ABSTRACT The behavior of butt-welded joint with imperfection of the outer contour due to sagging and continuous undercut has been analyzed in this paper. The analysis was done by testing and numerical investigation using Finite Element Analysis. For the testing, the standard probes have been made from material S235JR that is mostly used for the production of welded structures. Sagging and continuous undercut on both sides of the testing plates have been simulated in the welded joint in order to evaluate the imperfection. Research presented in this paper is directed in gaining acknowledgement and experience for analysis of the welded structures and their usage in design, construction, production and testing. In that manner the real picture of stress distribution is going to be acquired and this will contribute in the design of structures with decreased factor of safety leading to less expensive and yet safe structures which is the common interest of the companies that construct, produce and assemble welded structures. The purpose of this paper is to endorse the influence of the sagging and continuous undercut on the capacity of the welded joint in order to make appropriate judgment for the safety. Keywords: Butt-Weld, Continuous Undercut, FEA, Imperfection, Material Testing, Sagging. I. INTRODUCTION Due to discontinuities from various imperfections found on the outer contour of the welded joint (such as sagging and continuous undercut), there is irregular stress distribution at the joint with
  • 2. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME elevated stress peaks. The influence of these peaks cannot be precisely estimated during the calculation of the joint. In practice, the solution of the problem, in order to prevent the existence of such imperfections, lays in establishment of rigorous criteria prescribed by the regulation. Sometimes there is a question whether these rigorous criteria are reasonable due to the fact that they directly influent the costs of the welded structure. On the other side, in some separate cases as far as there is discontinuity, it is very likely that during the reparation the situation might worsen, particularly if there is a location where the reparation is hard to be made. Considering these facts, in some cases, it is necessary to make judgment whether there is need to make reparation on the discontinuities found on the outer contour during the examination. In this paper has been analyzed the behavior of butt-welded joint with imperfection of the outer contour due to sagging and continuous undercut. The probes used for the tensile, bending and toughness tests are standard and they are produced from the plates [2] made from material S235JR that is mostly used for the production of welded structures. Chemical composition and mechanical properties have been obtained by analyzing the material. Appropriate welding technology for the probes has been adopted according to EN499 and E7018 according to AWSA 5.2. the technology has been verified and appropriate WPQR certificate has been issued. Sagging and continuous undercut on both sides of the testing plates (probes) were simulated at the welded joint. Static examination of the basic material S235JR and the welded joint are made. The joints are analyzed by FEA in their real dimensions of the model and the imperfections with the ALGOR software [4]. Such analysis has shown the stress distribution of the joint. Research presented in this paper is directed in gaining acknowledgements and experience for analysis of the welded structures and their usage in design, construction, production and testing. In that manner is going to be acquired the real picture of stress distribution that will contribute in the design of structures with decreased factor of safety leading to less expensive and yet safe structures that are the common interest of the companies which project, produce and assemble welded structures. 8 II. BASIC MATERIAL Models (probes) analyzed in this paper are produced from material S235JR. The material has been tested in the laboratory and properties of material gained from the test are presented in Table 1 and Table 2. Table 1: Chemical Composition of the material Chemical element (%) C Si Mn P S Cr Ni Al Cu Nb Ti Mo V B Cekv 0,11 0,08 0,58 0,013 0,012 0,03 0,02 0,043 0,03 0,02 0,01 0,01 0,01 0,0 0,213 Table 2: Mechanical Properties of the material Dimensions Fm (N) Tension Bending Toughness Reh (Mpa) Rm (MPa) A5 (%) Reh/Rm (mm) (0) (J) 9,5x24,6 L=118 L0=90 120980 366 517 31,5 0,71 Ø40 180 112 t= + 200C
  • 3. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 0 Tension test graph is presented on Figure 1. 07-19 © IAEME Fig. 1: Tension test graph for material S235JR From the performed tests, it can be concluded that chemical composit properties, the elongation, bending and toughness meet the requirements of the standard EN 10025 for the quality of the material S235JR. III. WELDING TECHNOLOGY Welding of the plates was performed with TIG welding procedure (141) for the root ARC welding procedure for filling and finish. ARC welding was performed with basic electrode type E424 32 X5 according to EN499 and E7018 according to AWSA 5.2 [3]. Fig. 2: Welding order: 1. Root -TIG (141), 2. Filling -ARC (111), 3. Finish - Professionally qualified welder who possesses valid certificates performed the welding. The prescribed welding technology was verified and the WPQR certificate has been issued IV. THE PROBES FOR THE TESTING From the Basic material using the presc prescribed welding technology appropriate plates are created for the purpose of the test. The characteristic imperfections (sagging and continuous 9 – 6340(Print), composition, mechanical weld and ARC (111) ribed
  • 4. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME undercut) are simulated at the joint. The imperfection models used in the further tests are presented in Table 3 Table 3: The Models (probes) used for the tests 10 Probe mark 1. Welded joint with grinded face and root 2.1 2. Weld with significant sagging on one side 2.6. 3. Weld with continuous undercut on both sides 2.7. IV.1. PERMITTED DEVIATION OF THE IMPERFECTIONS The characteristic imperfections according to ISO 6520, depending on the level of quality of the weld are presented in Table 4. Table 4: Permitted deviation of the imperfections according to ISO 6520 Appearance of the imperfection t (mm) Boundary values of the imperfection for the level of quality D C B 2.6. 3 Small sizes h0,25 t no max 2 mm for probe 2.6 h2,375 mm Small sizes h0,1 t no max 1 mm for probe 2.6 h0,95 mm Small sizes h0,05 t no max 0,5 mm for probe 2.6 h0,475 mm 2.7. 3 h0,2 t no max 1 mm for probe 2.7 h1,9 mm h0,1 t no max 0,5 mm for probe 2.7 h0,95 mm h0,05 t no max 0,5 mm for probe 2.7 h0,475 mm IV.2. VISUAL EXAMINATION OF THE WELDED JOINTS Visual examination and dimensional control of the welded joints are performed in order to evaluate the imperfections. The results from the dimensional control of the imperfections are presented in Table 5. Table 5: Results from the dimensional control Joint with significant sagging 2.6. a1 (mm) b1 (mm) a (mm) b (mm) c (mm) 7,6 2 14 1 1 Joint with continuous undercut 2.7. a1 (mm) b1 (mm) a (mm) b (mm) c (mm) c1 (mm) 6,4 2 16,4 2 2 2 t h t h
  • 5. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME IV.3. RADIOGRAPHIC CONTROL OF THE JOINTS Welded probes – plates are radiography tested. The radiograms are presented in Table 6 Table 6: Radiograms Welded joint with grinded surfaces Mark Model Radiogram 11 2.1. Grinded face and grinded root 2.6. Significant sagging 2.7. Continuous undercut The defects are clearly recognizable on the radiogram. V. TESTING OF THE WELDED JOINTS Tensile, bending and toughness tests are performed in order to examine the effect of the imperfection V.1 TENSILE TEST The tensile test was performed on both the basic material and the samples without (2.1) and with imperfections (2.6 and 2.7). The tensile test graph for the basic material is presented on figure 2. The results from the tensile tests for the models 2.1, 2.6 and 2.7 and for the basic material marked with 2. are presented in Table 7. Table 7: The results from the tensile test Test probe Probe dimension A0 (mm2) Rp0,2 (N/mm2) Breaking force Fm(N) Rupture stress Rm (N/mm2) Location of rupture 2. 9,5 x 24,6 233,70 366 120980 517 5=31,5% 2.1 9,2 x 24,2 220,80 386 123290 558 Basic material 2.6 8,8 x 24,2 212,96 393 126580 594 Basic material Zone of the 2.7 8,8 x 24,5 215,60 355 119520 554 temperature influence
  • 6. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME All of the welded plates have equal nominal thickness. Therefore, at the location of the joint, the widths of the probes are approximately equal. The cross sectional area at the location of the rupture changes due to the different size (depth of the imperfection). At the welded structures where the joints are butt-welded the area of the cross-section has to be constant. For the calculation of the butt-welded joint according to the existing standards, the thickness of the weld is permanently considered as equal to the thickness of the basic material. Then, for different nominal cross section, for defining of the capacity, for comparison most relevant element is the breaking force Fm (N) acquired from the test. The intensity of the breaking force is presented on Figure 3. Fig. 3: The breaking force Fm(N) 12 V.2 BENDING TEST The results from the bending test of the basic material (signed with 2.), the welded joint with no imperfection (signed with 2.1) and welded joints with appropriate imperfections (signed with 2.6 and 2.7) are presented in Table 8 Table 8: Results from the bending test Test probe Type of test Dimension (mm) Diameter of bend former (mm) Shoulders distance (mm) Bending angle (0) 2. RBB/FBB 10x30 Ø40 70 180 2.1 RBB/FBB 10x30 Ø40 70 180 / 180 2.6 RBB/FBB 10x30 Ø40 70 180 / 180 2.7 RBB/FBB 10x30 Ø40 70 180 / 180 V.3. TOUGHNESS TEST The results from the toughness test of the basic material (signed with 2.), the welded joint with no imperfection (signed with 2.1) and welded joints with appropriate imperfections (signed with 2.6 and 2.7) are presented in Table 9. The test was performed according to EN875
  • 7. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME Table 9: Results from the toughness test 13 Probe mark Dimension of the probe a x10 x 55 Temperature (0C) A0 (cm2) Deformation energy (J) Calculated toughness (J/cm2) Location of the groove Type of 1 2 3 Sr. 1 2 3 Sr. groove 2. V 9,2x10x55 +20 0,74 78 138 120 112 105 187 163 151 Middle of the weld V 2.1 V 9,2x10x55 +20 0,736 144 104 90 112 195 141 122 152 Middle of the weld V 2.6 V 11,0x10x55 +20 0,88 191 294 207 230 217 334 235 262 Middle of the weld V 2.7 V 12,5x10x55 +20 1,0 262 294 295 283 262 294 295 283 Middle of the weld V According to the analysis of the results of the toughness test it can be concluded: - Obtained values of the toughness material meet the requirements for the toughness of the material S235JR at the temperature of +200C. Minimum required is 27 J - Since the groove of the probe is located in the middle of the joint, discontinuities 2.1, 2.6 and 2.7 do not influence the toughness. VI. FINITE ELEMENT ANALYSIS OF THE IMPERFECTIONS Plane strain models for the analysis of the considered cases were used. The analysis was performed with ALGOR software. The models are loaded with Fsr=65KN, force that delivers stress condition close to the yielding. The Yield stress measured from the tensile test is used as load criteria in the Finite Element Model. For the material S235JR the load is Rp=366 N/mm. According to EN 10025, the material has minimum yield stress Reh=235 N/mm2. In such case the proper value is the one measured from the tensile test Rp(0,2)=366 N/mm2. The Young modulus for all the analyzed cases is 2,1x105 N/mm2. In the Finite Element Model, at the locations of the imperfections the finer mesh has been used. [4]. VI.1. STRESS DISTRIBUTION DUE TO THE IMPERFECTIONS VI.1.1. WELDED PLATE WITHOUT IMPERFECTIONS (GRINDED FACE AND ROOT – MODEL 2.1) The real model and the Finite Element Model are presented on Figure 4. Fig. 4: The real model and the Finite Element Model for the case 2.1
  • 8. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 0 The stress distribution is presented on Figure 5 07-19 © IAEME Fig. 5: The stress distribution for the case 2.1 (no imperfection) VI.1.2. WELDED PLATE WITH SAGGING (MODEL 2.6) The real model and the Finite Element Model are presented on Fi Fig. 6: The real model and the Finite Element Model for the case 2.6 14 Figure 6. – 6340(Print),
  • 9. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 15 The stress distribution is presented on Figure 7 Fig. 7: The stress distribution for the case 2.6 (sagging) VI.1.3. WELDED PLATE WITH CONTINOUS UNDERCUT (MODEL 2.7) The real model and the Finite Element Model are presented on Figure 8. Fig. 8. The real model and the Finite Element Model for the case 2.7
  • 10. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME 16 The stress distribution is presented on Figure 9 Fig. 9: The stress distribution for the case 2.7 (continuous undercut) VI.2. ANALYSIS OF THE RESULTS FROM THE FEA Stress distribution at the welded joint for different cases (models) is presented on Figures 5, 7 and 9. At sufficient distance from the welded joint there is steady stress condition. If the stress distribution is analyzed, it may be concluded that at the locations where the continuity is interrupted (imperfection) there is existence of the stress peak. These peaks are close to the values of the yield stress of the basic material. Analyzing the results of the FEA, the following may be summarized: - The Imperfections (defects) have significant influence on the stress distribution, - When the model is loaded with the force Fsr, near the defects (discontinuities), the stress achieves the values close or equal to the yield stress of the material, - The verification of the proper modeling is the fact that far enough from the weld there is steady stress that in fact is the stress delivered when the force Fsr is divided by the cross-sectional area of the plate (the probe). VII. COMPARATIVE ANALYSIS AND THE REVIEW OF THE RESULTS The results from the tensile test of the basic material S235JR and the welded plates with various imperfections are presented in table 7. For defining of the capacity of the joint the most proper element for comparison is the value of the breaking force Fm. The value of the breaking force graphically is presented in Figure 30. The Material S235JR is characterized by good strength properties and good weldability. The results from the tensile test are: - Yielding stress Rp0,2=366 N/mm2, - Rupture stress Rm=517 N/mm2, - Breaking elongation 5=31,5%. According to the provided strength and deformation properties and the chemical composition it can be concluded that the material S235JR for the butt-welded profiles (2.1, 2.6 and 2.7), completely fulfills the requirements of the standard EN 10025.
  • 11. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME The breaking force from the tensile test of the joint with grinded face and root (2.1) is 17 Fm (2.1)=123290 N. This force is approximately equal with the breaking force of the basic material Fmom.=120890 N. The variation is within the tolerant limits. The rupture occurred in the basic material. From the bending test of the probe 2.1 has been obtained bending angle of 1800. It means that in both cases the criteria of the used bending test standard has been fulfilled. The results from the toughness test of the probe 2.1 are presented in the table 14. The measured values for the toughness fulfill the requirements for the material S235JR at the temperature of +200C. Minimum required value is 27J Permitted depth of the sagging depending on the level of quality is presented in Table 10 and the measured dimensions of the weld with sagging are presented in Table 11. Table 10: Permitted values of the sagging Level of quality D C B Depth of the sagging h (mm) 2,375 0,95 0,475 Depth of the sagging h (mm) - maximum allowed 2,00 1,00 0,50 Table 11: Measured dimensions of the sagging Probe Depth of the sagging h (mm) 2.6 1,00 From the visual examination and dimension control can be concluded that welded probe 2.6 does not fulfill the criteria for the level of quality C and B. From the tensile test of the welded probe 2.6, the measured breaking force is Fm (2.6)=126580 N. By comparing the results from the basic material (probe 2.) and the weld without imperfections (grinded face and root - probe 2.1) can be summarized: - The breaking force Fm (2.6) is superior than breaking forces of the basic material and the probe 2.1 - The rupture occurred at the basic material - The stress concentration due to imperfection of the outer contour (Figure 7) does not influence the capacity of the joint in the static loading condition. This is due to superior ductility of the material S235JR. From the bending test of the probe 2.6 (Table 8) the bending angle of 1800 has been measured. It proves that in both cases the required criteria from the bending test standard has been fulfilled. From the toughness test of the probe 2.6, (Table 9) have been measured toughness values that fulfill the requirements of the toughness of the material S235JR on +200C (probes 2.6) Permitted depth of the continuous undercut depending on the level of quality is presented in Table 12 and the measured dimensions of the excess metal are presented in Table 13. Table 12: Permitted values of the continuous undercut Level of quality D C B Depth of the root h (mm) 1,90 0,95 0,475 Depth of the root h (mm) - maximum allowed 1,00 0,50 0,50
  • 12. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME Table 13: Measured dimensions Probe Depth of the root h (mm) 2.7 2,00 From the visual examination and dimension control can be concluded that welded probe 2.7 does not fulfill the criteria for the level of quality D, C and B. From the tensile test of the welded probe 2.7, the measured breaking force is Fm (2.7) is superior than capacity of the probe 2.1. This 18 (2.7)=119540 N. By comparing the results from the basic material (probe 2.) and the weld without imperfections (grinded face and root - probe 2.1) can be summarized: - The cross sectional area of the probe 2. is A0 (2)=233,70mm2, and of the probe 2.7 is A0 (2.7)=215,60mm2. It gives A0 (2.7)=0,92A0 (2). After performing the reduction Fm (2.7)=130000 N. Reduced capacity of the probe 2.7, Fm proved that the decreasing of the carrying capacity of the model 2.7 Fm (2.7)=119520 N is result of decreased cross-sectional area due to the continuous undercut. - The rupture occurred in the zone of the thermal influence. This is result of the location of the zone of thermal influence where by undercut the cross-section is decreased. - The stress concentration due to discontinuity of the outer contour (Figure 9) does not influence the capacity of the welded joint in the condition of static loading. From the bending test of the probe 2.7 and both the root in compressed zone and the root in tension zone the requirements for the bending tests are fulfilled. In both cases the bending angle of 1800 has been achieved. From the toughness test of the probes 2.7 (table 12) are obtained values for toughness that meet the requirements for the toughness of the material S235JR at +200C. (Probe 2.7) VIII. CONCLUSIONS From the FEA, the experiments and the analysis of the results from the research it may be concluded: • The material S235JR of the probes with butt-welds (2.1, 2.6 and 2.7) completely fulfills the requirements of the standard EN10025. The material has good weldability and due to increased ductility is less sensitive to the stress concentration. • Superior sagging (probe 2.6) depending on the depth can influence the capacity of the joint in static (and presumably in dynamic conditions). The depth of the sagging fulfills the permitted value for class of quality D (h=1 mm 2mm), but does not fulfill the permitted limits for the class B (h=1mm 0,5 mm) and h=1 mm = 1mm (class C). • The high continuous undercut (probe 2.7) depending on the depth has influence of the weld capacity. The depth of the weld with continuous undercut is higher than the permitted value for D, C and B level of quality. • In the static loading conditions, during the quality assessment of the welded joints in the aspect of imperfections that cause discontinuity of the outer contour can be allowed certain violation of the imperfection dimensions compared to the permitted values of the standard ISO 6520. • During the quality assessment of the welded joints it should be considered the level of stress at the weld, the kind of the stress and the kind of the loading of the structure. • During the quality assessment of the welded joints, particularly the dynamically loaded joints, the material of the welded structure must be considered. That is due to the fact that different materials have different sensibility of the stress concentration.
  • 13. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 8, August (2014), pp. 07-19 © IAEME • Having in mind the knowledge gained from this paper, in certain cases the certain welds may be judged positive even when there are present some imperfections, particularly imperfections in the outer contour. For delivering such judgment, the person must have good understanding of materials, welding, construction, design, calculation etc. 19 REFERENCES [1] Werner Mewes; Kleine Schweibkunde fur Maschinenbauer, 2 Auflage, VDI-Verlag GmbH, Du basic material Dusseldorf 1992. [2]
  • 14. .:
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  • 20. , 1982 [4] Zienkiewicz O.C., Taylor R.Z.: The Finite Element Method, Vol 1, Vol. 2, McGraw-Hill, London, 1991. [5] Leung A. Y. T.: Dynamic Analysis of Thin-Walled Structures, Journal of Thin-Walled Structures, Volume 14, Issue 3, pp.209-222, Elsevier Science Ltd., 1992. [6] Vinson J.R.: The Behavior of Thin Walled Structures: Beams, Plates and Shells, Kluwer Academic publishers, Doredecht, 1989. [7] Neumann A., Schweibtechnisnes Handbuch fur Konstrukterre” – Teil 1, DVS – Verlag GmbH, Dusseldorf, 1996. [8] Neumann A., Schweibtechnisnes Handbuch fur Konstrukterre” – Teil 3, DVS – Verlag GmbH, Dusseldorf, 1996. [9] Neumann A., Kompendium der Schweibtechnik”, Band 4: Berechung und Gestaltung von schweib konstruktionen, DVS – Verlag, Dusseldorf, 1997. [10] P.Govinda Rao, Dr.Clvrsv Prasad, Dr.S.V.Ramana and D.Sreeramulu, “Development of Grnn Based Tool for Hardness Measurement of Homogeneous Welded Joint Under Vibratory Weld Condition”, International Journal of Advanced Research in Engineering Technology (IJARET), Volume 4, Issue 4, 2013, pp. 50 - 59, ISSN Print: 0976-6480, ISSN Online: 0976- 6499. [11] P. Govinda Rao, Dr. C L V R S V Prasad, Dr.D.Sreeramulu, Dr.V. Chitti Babu and M.Vykunta Rao, “Determination of Residual Stresses of Welded Joints Prepared Under the Influence of Mechanical Vibrations by Hole Drilling Method and Compared by Finite Element Analysis”, International Journal of Mechanical Engineering Technology (IJMET), Volume 4, Issue 2, 2013, pp. 542 - 553, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359. [12] P. Govindarao, Dr. P. Srinivasarao, Dr. A. Gopalakrishna and C V Sriram, “Improvement of Tensile Strength of Butt Welded Joints Prepared by Vibratory Welding Process”, International Journal of Mechanical Engineering Technology (IJMET), Volume 4, Issue 4, 2013, pp. 53 - 61, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359.