Calculation of weld toe stresses from global numerical models: An engineering-oriented approach

Investigating geometric details with local stress concentration requires advanced numerical models that rely on huge computational efforts to refine global structures. Unfortunately, the required computational effort often outweighs the benefits due to uncertainties related to real loading conditions, thus yielding predictions that are relatively precise but financially burdensome. This paper presents a methodology for safely estimating local stresses at weld toe details using conventional structural models based on beam elements and nominal stress calculations. The proposed approach determines design load effects and time histories, providing a balance between computational efficiency and accuracy. Validation is carried out through direct strain measurements on a real railway bridge and a detailed multi-scale finite element model. This methodology offers a practical tool for prioritizing fatigue damage assessment in structural components, particularly in light of the release of the new Eurocode EN1993-1-14.