Adhesive Joining Technology for Manufacturing of the Composite Flexspline for a Harmonic Drive

A new manufacturing method for the cup-type composite flexsplinc drive was developed using adhesive joining technology to obviate the manufacturing difficulty of the conventional one-piece cup-type steel flexspline and to improve the dynamic characteristics of the flexspline.

In this method, the boss, tube and tooth sections of the flexspline were designed and manufactured separately, and adhesively bonded. The tube section was manufactured with high strength carbon fiber epoxy composite material and its dynamic properties were compared with those of the conventional steel flexspline.

The torque transmission capability of the adhesively-bonded joint was numerically calculated using the nonlinear shear stress-strain relationship which was represented by an exponential form.

From the test results of the manufactured composite flexspline and the conventional flexspline, it was found that the manufactured composite flexspline had better torque transmission characteristics. Also, it was found that the damping capacity of the composite flexspline was considerable improved.     

The Torque Transmission Capabilities of the Adhesively-Bonded Tubular Single Lap Joint and the Double Lap Joint

With the wide application of fiber-reinforced composite materials in aircraft, space structures and robot arms, the design and manufacture of composite joints have become a very important research area because they are often the weakest areas in composite structures.

In this paper, the stress and torque transmission capabilities of the adhesively-bonded tubular single lap joint and the double lap joint were experimentally tested. In order to compare the experimental results with the calculated results, the stress and torque transmission capabilities were analyzed by the 3-dimensional finite element method taking into consideration the nonlinear properties of the adhesive.

From the experiments it was found that the torque transmission capabilities of the adhesively-bonded double lap joint was 2.7 times as large as that of the single lap joint. Also, it was found that the fatigue limit of the double lap joint was 16 times as large as that of the single lap joint.     

A Closed-form Solution for the Torque Transmission Capability of the Adhesively Bonded Tubular Double Lap Joint

The adhesively bonded tubular double lap joint has better torque transmission capability and reliability in bonding than the single lap joint.

In this paper, an analytic solution for the torque transmission capability and stress distribution of the adhesively bonded tubular double lap joint was derived assuming linear properties of the adhesive.

From the analytic solution, it was found that the torque transmission capability of the double lap joint was more than 40% larger than that of the single lap joint.     

Development of a Fatigue Failure Model for the Adhesively Bonded Tubular Single Lap Joint under Dynamic Torsional Loading

The adhesively bonded tubular single lap joint shows nonlinear torque transmission capability and deformation characteristics under static torsional loading because of nonlinear properties of the adhesive. However, the dynamic or fatigue torque transmission capability can be calculated with linear, analysis because the stress-strain relation under torsional fatigue loading is linear, due to the small dynamic transmission capability compared with the static torque transmission capability.

In this paper, a failure model for the adhesively bonded tubular single lap joint under torsional fatigue loading was developed with respect to the adhesive thickness, which is the critical factor for the static torque transmission capability. Also, a design method for the adhesively bonded tubular single lap joint under torsional fatigue loading was proposed.     

An Iterative Solution for the Torque Transmission Capability of Adhesively-Bonded Tubular Single Lap Joints with Nonlinear Shear Properties

The adhesively-bonded tubular single lap joint shows large nonlinear behavior in the load-displacement relationship, because structural adhesives for the joint are usually rubber-toughened, which endows adhesives with nonlinear shear properties. Since the majority of load transfer of the adhesively-bonded tubular single lap joint is accomplished by the nonlinear behavior of the adhesive, its torque transmission capability should be calculated using nonlinear shear properties. However, both the analytic and numerical analyses become complicated if the nonlinear shear properties of the adhesive are included during the calculation of torque transmission capabilities.

In this paper, in order to obtain the torque transmission capabilities easily, an iterative solution which includes the nonlinear shear properties of the adhesive was derived using the analytic solution with the linear shear properties of the adhesive. Since the iterative solution can be obtained very quickly due to its simplicity, it has been found that it can be used in the design of the adhesively-bonded tubular single lap joint.     

Nonlinear Analysis of theTorque Transmission Capability of Adhesively Bonded Tubular Lap Joints

Calculated torque transmission capability of adhesively bonded tubular lap joints using linear elastic material properties is usually much less than the experimentally-determined one because the majority of the load transfer of the adhesively bonded joints is accomplished by the nonlinear behavior of rubber-toughened epoxy adhesives.

Although the adhesively bonded tubular double lap joint has better torque transmission capability and reliability than the single lap joint, the nonlinear analytic or numerical analysis for the adhesively bonded tubular double lap joint has not been performed because of numerical complications.

An iterative solution that includes the nonlinear shear behavior of the adhesive was derived using the analytic solution. Since the iterative solution can be obtained very quickly due to the simplicity of the algorithm, it is an attractive method of designing adhesively bonded tubular single and double lap joints.     

Torque Transmission Capabilities of Bonded Polygonal Lap Joints for Carbon Fiber Epoxy Composites

Although carbon fiber epoxy composite materials have excellent properties for structures, the joint in composite materials often reduces the efficiency of the composite structure because the joint is often the weakest area in the composite structure.

In this paper, the effects of the adhesive thickness and the adherend surface roughness on the static and fatigue strengths of adhesively-bonded tubular polygonal lap joints have been investigated by experimental methods. The dependencies of the static and fatigue strengths on the stacking sequences of the composite adherends were observed.

From the experimental investigations, it was found that the fatigue strength of the circular adhesively-bounded joints was quite dependent on the surface roughness of the adherends and that polygonal adhesively-bonded joints had better fatigue strength characteristics than circular adhesively-bonded joints.     

Analysis of the Tubular Single Lap Joint with Nonlinear Adhesive Properties

The majority of the load transfer of an adhesively-bonded joint is accomplished by the nonlinear behavior of the adhesive. In this paper, the torque transmission capability and shear stress distribution of the tubular single lap joint were calculated by incorporating the nonlinear shear properties of the adhesive. The nonlinear shear properties were represented by three different mathematical models such as two-parameter exponential, linear perfectly-plastic and multilinear strain-softening approximations.

From the analyses and experiments, it was found that all the analyses with nonlinear approximations predicted the torque transmission capabilities accurately, but the two-parameter exponential approximation gave the best predictions with the simplest form for use in numerical calculation.     

Development of a Failure Model for the Adhesively Bonded Tubular Single Lap Joint

The accurate calculation of the stresses and torque capacities of adhesively bonded joints is not possible without understanding the failure phenomena of the adhesive joints and the nonlinear behavior of the adhesive.

In this paper, an adhesive failure model of the adhesively bonded tubular single lap joint with steel-steel adherends was proposed to predict the torque capacity accurately.

The model incorporated the nonlinear behavior of the adhesive and the different failure modes in which the adhesive failure mode changed from bulk shear failure, via transient failure, to interfacial failure between the adhesive and the adherend, according to the magnitudes of the residual thermally-induced stresses from fabrication.     

Physical Considerations in the Development of Pressure-Sensitive Adhesive Sheets

A pressure-sensitive adhesive sheet is a special kind of paper used in non-impact printers which use a heating process to apply toner to paper. As a result, it needs special characteristics that general pressure-sensitive adhesive paper for labels do not require.

One of these characteristics is that the edge of the folded paper used in non-impact printers must not incline after printing. This was done by making the degree of orientation of the fibers in the face stocks and the release liners low.

The other characteristics are that adhesive must not ooze out from the edges during the slitting or guillotining process and that the labels must not come off of the release liner by themselves during the printing process. Ooze characteristics were found to be related to the adhesive coat weight. An adhesive paper with both a high peel strength and lower adhesive coat weight was developed by studying the dynamic viscoelastic properties of adhesives and release layers. The storage modulus of the release layer concerned with the release force was also found to be related to the self-peeling tendency of the labels.

These points were considered during the development of pressure-sensitive adhesive paper used in non-impact printers which use a heating process to apply toner to paper.     

塑料谐波齿轮柔轮的结构和模具设计

用工程塑料替代钢制材料来构成某一谐波减速器,设计了满足传动要求的塑料柔轮参数和结构,并合理地设计了柔轮注塑模具;在模具设计中,运用计算机辅助工程（CAE）,验证了设计的浇注系统不会产生滞流现象,在冷却系统设计时,保证了柔轮内径的变形量小于0.3 mm,满足柔轮设计要求。     

Study of Polymer Blends as a Vibration Damper

Metallic materials have too small internal friction to damp vibration making noise, whereas plastics show remarkably large damping capacity in some characteristic temperature ranges where a considerable part of the vibrational energy is consumed as a result of molecular friction.

If the two kinds of materials are combined, one can expect that the vibration of the composite materials will be damped to a greater extent than that of the metal itself.

In this study dynamic mechanical properties of a variety of polymer blends were measured and those which have a broad E' peak around 0°C were chosen from among them.

Sandwich structures of Al/polymer/Al type were then constructed and the dynamic mechanical properties of the composite systems were measured by means of a vibration reed technique. It was found that the sandwich structures with these polymer blends had larger damping capacity than that with poly (vinyl acetate) or Al itself.     

Simulation Analyses on the Diffusion of a Rust-Preventing Oil into an Oil-Accommodating Adhesive

In recent years bonding between two steel plates was accomplished with an oil-accommodating adhesive without requiring degreasing of the steel. In this paper, the exclusion process of the oil was investigated in this adhesive on the assumption that the oil was absorbed into the adhesive layer.

It was found that the oil layer essentially disappeared in the initial step of curing in which the temperature was raised to 180°C, because the diffusion rate of the oil into the adhesive increased abruptly with temperature. Therefore, the bonding process in this case is not influenced by the presence of oil on the steel plates.     

The Role of the Interface in Carbon Fibre-Epoxy Composites

The final performance of a composite material depends strongly on the quality of the fibre-matrix interface. The interactions developed at the interface were studied using the acid-base or acceptor-donor concept.

The surface characteristics of the carbon fibres and the epoxy matrix were studied using a tensiometric method and the inverse gas chromatography technique. Acid-base surface characters could be determined allowing the interactions at the interface to be described by a specific interaction parameter.

It was shown that the shear strength of the interface, as measured by a fragmentation test, is strongly correlated to this specific interaction parameter, demonstrating the importance of acid-base interactions in the fibre-matrix adhesion.     

Durability of Adhesive Bonds to Zinc-Coated Steels: Effects of Corrosive Environments on Lap Shear Strength

The effects of corrosive environments on adhesive bonds to electro-galvanized, zinc/aluminum alloy coated, coated electro-galvanized, and cold-rolled steels have been investigated. Bonds prepared using a rubber-modified dicyandiamide-cured epoxy adhesive, an epoxy-modified poly(vinyl chloride)-based adhesive, an acrylic-modified poly(vinyl chloride)-based adhesive a one-part urethane adhesive, and a two-component epoxy-modified acrylic adhesive were exposed under no-load conditions to constant high humidity or cyclic corrosion exposure for 50 days or 50 cycles (10 weeks) respectively.

Over the course of this study, exposure to constant high humidity had little effect on lap shear strength for any of the systems studied. Bond failures were initially cohesive, and with few exceptions remained so.

Bond strength retention under the cyclic corrosion exposure conditions employed was strongly dependent on adhesive composition and on substrate type. On galvanized substrates, lap shear strengths for the poly(vinyl chloride)-based adhesives were reduced by 90-100% during the course of the corrosion exposure, and a change in the mode of bond failure (from cohesive to interfacial) was observed. On the coated electro-galvanized steel substrate, the poly(vinyl chloride)-based adhesives showed about 50% retention in lap shear strength and a cohesive failure throughout most of the corrosion test. The dicyandiamide-cured epoxy adhesive used in this study generally showed the best lap shear strength retention to zinc-coated substrates; bonds to cold-rolled steel were severely degraded by corrosion exposure. The performance of the acrylic and urethane adhesives were intermediate to the dicyandiamide-cured epoxy and poly(vinyl chloride)-based adhesives in strength retention.     

Fracture Toughness of Adhesive Joints

To define the influence of the processing variables on the resistance of epoxy joints to brittle crack extension during short loading times, the fracture toughness, g_ic, of the joints was measured as a function of the following variables:

1. Hardener type (TEPA vs. HHPA)

2. Ratio of hardener to resin content

3. Post-cure temperature

and 4. Joint geometry (thickness and width)

It was found that the toughness of the TEPA hardened system varied by a factor of four-to-one as the ratio of hardener to resin content and post-cure temperature varied within what might be considered reasonable limits for manufacturing. The toughness of the HHPA hardened system varied only over the middle half of this same range.

For both systems, toughness increased with joint thickness over the range of 2 to 50 mils.     

Outline of an Algorithm for Computation of the Strength of Polymer Adhesive Joints

An algorithm based on hierarchical polymer structure is proposed for calculation of the adhesive joint strength. This hierarchy enables one to describe the behavior of polymer adhesive joints taking into account specific characteristics of all the levels by combining together physico-chemical concepts of the formation of adhesive systems and their fracture mechanics.

In order to prove the validity of the described approach electroless copper plated ABS-copolymers were studied experimentally.

The developed approach makes it possible to take into consideration the effect of the parameters characterizing the formation of an adhesive joint on its strength properties.     

Application of Macromonomers for Pressure Sensitive Adhesives I. Adhesive and Surface Properties

Adhesive and surface-chemical properties of poly(styrene macromer-butyl acrylate) copolymers, poly (styrene-butyl acrylate macromer) copolymers and poly (styrene-butyl acrylate) random copolymers were investigated. The results were as follows:

(1) The adhesive properties of the copolymers which were prepared by the macromer-technique were different from the random copolymers.

(2) It was found that there were differences in the surface and molecular structure between the copotymers which were prepared by the macromer technique and the random copolymers. These differences were evident from the results of measurements of the surface free energy of the copolymers and of the interfacial tension of water/toluene in the presence of the copolymers.

(3) The reason why there were differences in the surface and molecular structure seemed to be that the copolymers which were prepared by the macromer technique had graft chains and a different inner-structure from the random copolymers. Therefore, it was suggested that the graft copolymers which were prepared by the macromer technique had a phase-separated structure.     

Transmission and Mechanical Properties of Optical Adhesives

The optical, mechanical and durability performance of selected epoxy, polyester, UV-curable acrylic, cyanoacrylate and silicone adhesives were evaluated and measured for bonding applications of optically transparent glasses in the visible and infra-red regions of the electromagnetic spectra.

From the initially selected adhesives only the UV-curable modified acrylic, two-component silicone and room temperature cured epoxy, were found to be of high performance characteristics, having good transmission properties and enhanced endurance in a combination of heat and humidity and following thermal cycling.

Sodium chloride substrates served as adherends for the transmission characterization of the optical adhesives, due to their high transmission properties in the 0.4-10 m μ spectral range. A modified lap shear specimen was designed for studying the mechanical properties and failure mechanisms of the adhesives and their durability in a humid and not environment. Finally, a two-piece glass doublet was used for investigating the optomechanical characteristics of the optical adhesive following environmental conditioning and thermal shock cycling.

Due to the inherent C-C bond, polymer adhesives are limited in utility, as far as transparency is concerned, close to 3.5 μm and in most of the 8-12 μm spectral range.     

Structural Adhesive Bonds to Primers Electrodeposited on Steel

Adhesive bond strength and durability were investigated for steel substrates which had been cathodically electroprimed before bonding. Lap shear and torsional impact strengths of two model epoxy adhesives were evaluated. Very poor strengths and durability were found for one adhesive, which was cured with a mixture of three amine curing agents. Scanning electron microscopy and analysis of primer susceptibility to interaction with the curing agents suggested that, for the high concentrations of curing agent in the amine-cured adhesive, chemical and physical degradation of the primer occurred during cure at elevated temperature.

For the second adhesive, which was cured with a single imidazole catalyst, excellent strength and durability were obtained, with no evidence of primer degradation. Surprisingly, for this adhesive, strengths to primed steel were up to 88% higher than to cleaned (i.e., degreased) bare steel. The concurrent improvements in environmental durability over bare steel, as assessed by water immersion and salt spray accelerated exposures, were attributed to the more favourable surface energetics of the adhesive/primer interface.