Actual geometries of welded structures are slightly deviated from the designed shapes due to the gas-cut surfaces along plate edges and due to the irregular shapes of weld beads with possible undercuts at weld toes. Although fatigue failures of welded structures may be initiated at these highly stressed regions, conventional finite element structural analyses are usually carried out disregarding these imperfection effects at the design stage. A second order perturbation method is proposed to the two-dimensional elastic problem of a semi-infinite plane, whose surface is slightly deviated from a straight line. The deviation, η, of the actual surface from the straight line is assumed to be small compared with the characteristic length of the problem, and it is taken as the perturbation parameter of the present formulation.The accuracy of the present method is first investigated by solving the problem of semi-elliptical notch in a semi-infinite plane under a combined uniform tension and in-plane bending at infinity. In comparing the present perturbation solution with other results, it is found that the peak stress can be estimated by the first order approximation with satisfactory accuracy, while the second order solution is necessary for the proper determination of the stress gradient at the peak point. The method is then applied to the problem of a slightly wavy surface, which is sometimes observed in actual weld beads. The peak stress and the stress gradient are calculated in closed forms up to the second order in terms of the height and wave length of the wavy surface. It can be seen that the present method is effective for the analyses of geometrical imperfections of arbitrary shapes, which may be difficult to analyze through the conventional structural design procedures of welded structures.
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