Numerical design and multi-objective optimisation of novel adhesively bonded joints employing interlocking surface morphology |
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| Affiliation: | 1. Helmholtz-Zentrum Geesthacht, Centre for Materials and Coastal Research, Institute of Materials Research, Materials Mechanics, Solid State Joining Processes, Geesthacht, Germany;2. Helmholtz-Zentrum Geesthacht, Centre for Materials and Coastal Research, Institute of Materials Research, Metallic Biomaterials, Materials Design and Characterisation, Geesthacht, Germany;3. Hamburg University of Technology, Institute of Polymer Composites, Hamburg, Germany;1. Laboratory of Technology & Strength of Materials, Department of Mechanical Engineering & Aeronautics, University of Patras, Patras 26500, Greece;2. Institute of Materials and Process Engineering, Zurich University of Applied Sciences, CH-8401 Winterthur, Switzerland;1. Engineering Mechanics Group, Institute of High Performance Computing, 1 Fusionopolis Way, Singapore 138632, Singapore;2. Additive Manufacturing Research Centre, School of Engineering, RMIT University, Melbourne, Australia;3. Sir Lawrence Wackett Aerospace Research Centre, School of Engineering, RMIT University, Melbourne, Australia;4. Joining Technology Group, Singapore Institute of Manufacturing Technology, 2 Fusionopolis Way, Singapore 138634, Singapore;1. Faculdade de Engenharia da Universidade do Porto, Departamento de Engenharia Mecânica, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal;2. IBM T. J. Watson Research Center, 1101 Kitchawan Road, Yorktown Heights, NY 10598, USA;1. Institute of Aircraft Design, University of Stuttgart, Pfaffenwaldring 31, 70569 Stuttgart, Germany;2. Institut für Kunststofftechnik, University of Stuttgart, Pfaffenwaldring 32, 70569 Stuttgart, Germany |
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| Abstract: | A novel concept for joining materials is presented which employs adhesive joints with interlocking bond-surface morphology formed on the surfaces of male and female adherends that mechanically interlock in shear when brought together. In the present work, miniature, single-lap joint specimens with a single truncated square pyramid interlocking profile, centred in the bond area, are investigated. The performance of the concept is assessed through finite element analysis (FEA) by incorporating yield criteria representing plasticity in the adherends and a cohesive zone model to represent damage in the adhesive layer. This allows for effective simulation of the joint response until ultimate failure and thus, full assessment of the concept's performance. Various interlocking geometries are explored and refined through an adaptive surrogate modelling design optimisation procedure coupled with FEA. The results indicated that significant improvements in work to failure, of up to 86.5%, can be achieved through the more progressive failure behaviour observed compared to that of a traditional adhesively bonded joint. Improvements in the joint's ultimate failure load can also be achieved with a relatively ductile adhesive system. |
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| Keywords: | Finite element stress analysis Cohesive zone model Adhesion by mechanical interlocking Hybrid joints Joint optimisation |
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