Stitch Weld Calculator

Stitch Weld Calculator

Determine the number of stitches, total weld length, and duty cycle for your intermittent welding project.

function calculateStitchWeld() { var totalSeamLength = parseFloat(document.getElementById('totalSeamLength').value); var weldLength = parseFloat(document.getElementById('weldLength').value); var gapLength = parseFloat(document.getElementById('gapLength').value); var resultDiv = document.getElementById('stitchWeldResult'); if (isNaN(totalSeamLength) || isNaN(weldLength) || isNaN(gapLength)) { resultDiv.innerHTML = 'Error: Please enter valid numbers in all fields.'; return; } if (totalSeamLength <= 0 || weldLength <= 0 || gapLength totalSeamLength) { resultDiv.innerHTML = 'Error: Individual weld length cannot be greater than the total seam length.'; return; } var numStitches = 0; var totalWeldLength = 0; var totalGapLength = 0; var weldPercentage = 0; if (gapLength === 0) { // Continuous weld numStitches = 1; totalWeldLength = totalSeamLength; totalGapLength = 0; weldPercentage = 100; } else { var cycleLength = weldLength + gapLength; var numFullCycles = Math.floor(totalSeamLength / cycleLength); var remainingLength = totalSeamLength – (numFullCycles * cycleLength); numStitches = numFullCycles; totalWeldLength = numFullCycles * weldLength; if (remainingLength > 0) { numStitches++; var finalStitchLength = Math.min(weldLength, remainingLength); totalWeldLength += finalStitchLength; } totalGapLength = totalSeamLength – totalWeldLength; weldPercentage = (totalWeldLength / totalSeamLength) * 100; } var resultHTML = '

Calculation Results:

'; resultHTML += 'Number of Stitches: ' + numStitches + "; resultHTML += 'Total Weld Length: ' + totalWeldLength.toFixed(2) + ' units'; resultHTML += 'Total Gap Length: ' + totalGapLength.toFixed(2) + ' units'; resultHTML += 'Weld Duty Cycle: ' + weldPercentage.toFixed(2) + '% of the seam is welded'; resultDiv.innerHTML = resultHTML; }

Understanding Stitch Welding

Stitch welding, also known as intermittent welding, is a technique where a series of short welds (stitches) are made along a joint with unwelded spaces (gaps) in between. This method contrasts with a continuous weld that runs the entire length of the seam. It is commonly used in sheet metal fabrication, automotive bodywork, and situations where controlling heat input is critical.

How to Use the Stitch Weld Calculator

To effectively plan your project, enter the following parameters into the calculator:

• Total Seam Length: The full length of the joint you need to weld. Ensure you use a consistent unit (like mm, cm, or inches) for all inputs.
• Individual Weld (Stitch) Length: The desired length for each single weld bead.
• Gap Length Between Welds: The length of the unwelded space you want to leave between each stitch.

The calculator will then provide the total number of stitches required, the total length of welding needed, the total length of all gaps, and the weld duty cycle, which is the percentage of the seam that is actually welded.

Example Calculation

Imagine you are welding a reinforcement panel onto a car's chassis. The total seam length is 1500 mm. Your engineering specification calls for 40 mm stitches with a 100 mm gap between them to manage heat and prevent warping.

• Total Seam Length: 1500 mm
• Weld (Stitch) Length: 40 mm
• Gap Length: 100 mm

Based on these inputs, the calculator would determine that you need 11 stitches, resulting in a total weld length of 440 mm and a weld duty cycle of approximately 29.33%.

Why Use Stitch Welding?

Stitch welding offers several advantages over continuous welding in specific applications:

• Heat Distortion Control: By applying less heat overall and allowing sections to cool, stitch welding significantly reduces the risk of warping and distortion, especially on thin materials.
• Cost and Time Savings: It requires less filler material and can be faster to execute than a continuous weld over a long seam, reducing labor and material costs.
• Sufficient Strength: For many applications that do not require a fully sealed or maximum strength joint, stitch welding provides more than adequate structural integrity.
• Flexibility: It allows for slight movement or flex in the joint, which can be beneficial in applications subject to vibration or thermal expansion.

Key Stitch Welding Terminology

Stitch Length

The measured length of a single, individual weld bead in an intermittent pattern.

Gap Length

The unwelded space or distance between two consecutive stitches.

Pitch

The center-to-center distance between two consecutive stitches. It is calculated as (Stitch Length + Gap Length).

Weld Duty Cycle

The ratio of the total length of all welds to the total seam length, expressed as a percentage. It indicates how much of the joint is actually welded.