A Parametric Approach to Strength Optimization of Adhesive Joints using Geometric Technique
One of the main reasons for the increasing use of adhesive bonding is the fact that the stress distribution is more uniform than with other conventional methods of joining which enables to reduce weight. However, even in adhesive joints the stress distribution is not per
2025-06-28 16:30:06 - Adil Khan
A Parametric Approach to Strength Optimization of Adhesive Joints using Geometric Technique
Project Area of Specialization Internet of ThingsProject SummaryOne of the main reasons for the increasing use of adhesive bonding is the fact that the stress distribution is more uniform than with other conventional methods of joining which enables to reduce weight. However, even in adhesive joints the stress distribution is not perfectly uniform and this leaves room for improvements. The major enemy of adhesive joints is peel or cleavage stresses.
These should be reduced if strong joints are to be designed.The focus is on lap joints because these are the most common. Methods are then proposed to improve the joint strength by using fillets, adherend profiling, and other geometric solutions.The main rule for all cases is to spread the load over a large area and reduce the peel stresses.
Following are objectives which we wish to impliment and obtain from our respective project.
- To study a single lap joint using adhesive and methods are then proposed to improve the joint strength by using
- fillets,
- adherend profiling and
- other geometric solutions.
- To Analyze the shear and peel stresses on adhesive joints using FEM on a software.
We divided our project into four Quarters.
In the first quarter, the aspects of Literature Review are covered. Literature Review is comprised of research papers, journals and articles.
In the second quarter of this project, we will deal with the Selection and Procurement of adhesive and adherends. We have opted Huntsman Araldite 2011 All-Purpose epoxy as our adhesive material and Aluminum sheets (6061-imported sheet) as our adherent.
The third quarter comprises of the preparing of different geometric solutions which include (a) Simple single lap joints, b) Simple single lap double thickness, c) Single hole, d) Double longitudinal hole, e) Double crosswise hole, f) Scarf, g) Scarf double thickness, h) Half tapered, i) Tapered joints. Then, the surface treatment will be done on the adhering surface to allow more grip between the adherends. And lastly, the mold will be prepared to hold the adherents stationary while applying the adhesive to attain perfection.
Last, but not the least was the Fourth Quarter, will be the comparison of the experimental results with the FEA results using ABAQUS. We will compare the shear and peel stresses of different Geometric Solutions.
Benefits of the ProjectThe main goal which we wish to achieve is to reduce shear and peel stresses which will increase the overall strength of adhesively bonded joint, thus expanding the use of adhesive over welding anfd other joining techniques. The main concern of working on increasing the strength of adhesive is that, they are easy to be applied without requiring any special expertise, and most importantly, it doesnt requires any special tool unlike welding and riveting.
Other important use of adhesive is in Aerospace industry, as manufacturing of plane requires lighter material, and by using adhesives on contrast to conventional joining methods can greatly reduce the weight of aircraft.
Technical Details of Final Deliverable- 6061-T6 Aluminum Sheet (4*8 ft)
- Huntsman Araldite 2011 All-Purpose epoxy (Imported from Amazon USA) x2
- Shearing the Aluminum sheet into small coupons of dimensions (25.4x101.6mm)x180 pieces
- Making Geometric Profiles (Rounding, InternalTapering and External Tapering)
- Rounding=2mm, 3mm, 4mm
- Internal Tapering=30, 35, 45degree
- External Tapering=30, 45, 60degree
- Total Geometric Configuration=90
- Testing of coupon on Universal Testing Machine
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 58135 | |||
| Aluminum 6061-T6 Sheet | Equipment | 1 | 10500 | 10500 |
| Huntsman Araldite 2011 All-Purpose epoxy | Equipment | 2 | 12500 | 25000 |
| Shearing of sheet into Coupons | Equipment | 180 | 15 | 2700 |
| Making Geometrical Profiles | Equipment | 80 | 40 | 3200 |
| Distilled Water | Equipment | 2 | 200 | 400 |
| Sodium Hydroxide | Equipment | 1 | 1700 | 1700 |
| Testing of coupons in UTM | Equipment | 45 | 103 | 4635 |
| Transport Charges | Miscellaneous | 1 | 10000 | 10000 |