Finite Element Analysis Of Simple Butt Type Adhesive Joint .

International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.comFinite Element Analysis of Simple Butt TypeAdhesive Joint Using RADIOSSMr. Mahesh Shivaji KadamAssistant Professor, Mechanical Engineering DepartmentSanjay Ghodawat Group of Institutions,Atigre, Kolhapur, IndiaDr. Vivek V. KulkarniProfessor & Dean Academics, Mechanical Engineering DepartmentSanjay Ghodawat Group of Institutions,Atigre, Kolhapur, Indiaparameters of the bonded materials as well as on those of theadhesive layer. [1]AbstractMajority of automobile and aerospace parts, mainly their bodycomponents are joined together by different types ofadhesives. So these growing needs demand the detailed studyon stress concentration and strength analysis of adhesivejoints. With the help of structural analysis simulations we canidentify the problem areas, failure loads and solutions can bevalidated in computers without any expensive shop flooroperations prior to any tool construction. Structural analysissimulation is also helpful at the joint design stage to decidevarious parameters, like material used, load applied etc. In therecent years the use of finite element analysis is increased inthe strength analysis of sheet metal joints. Finite elementanalysis helps to analyze the process virtually.The present investigation reports a case study of a butt typeadhesive joint of similar and dissimilar metals. This joint issubjected to static tensile loading and the RADIOSS deck ofHyperworks 11.0 software package is used to carry out theanalysis. The analysis result helps in depicting the effects ofvarying load and material used on stress induced and hence onthe joint strength of metal to metal butt type adhesive jointunder static tensile loading is studied in this case study.Investigator considered the mechanical behavior and failureunder proportional, multi-axial loading using an instrumented,Arcan-type test. The statistical behaviour, also observed witha simple tensile test, seems to be related to the heterogeneousnature of the microstructure of the adhesive bond, whichcontains voids, as well as mineral particles for reinforcement.It is concluded that the statistical aspects of porositydistribution can clearly be seen to depend on several factors,such as the type of adhesive paste, the operator and the mixingprocess. Dispersion and distribution of porosities can explainthe variability of fracture strength in mechanical testingduring adhesive characterization. [2]Researcher investigated the effect of adhesive thickness ontensile and shear strength of a polyimide adhesive. Tensileand shear tests are carried out using butt and single lap joints.And concluded that the tensile strength for butt joint decreaseswith increasing adhesive thickness and shear strength forsingle lap joint is almost constant regardless of adhesivethickness, although a lot of scatter is observed in the tensileand shear strength of polyimide adhesive. The fabricatedjoints using the polyimide adhesive failed in an interfacialmanner regardless of adhesive thickness. [3]Keywords: Stress concentration, Strength analysis, Butt typeadhesive joints and Adhesive thickness.IntroductionThe influence of static tensile loading on stress distributionwithin the adhesive joint is analyzed by finite element method.Practically Von Mises stresses are maximum at edge anddecreases away from edge. Similarly shear stresses almostvanish towards the middle of the adhesive. The shear stresscontribution to the Von Mises stress is significant in the bondregion close to the metal plate; this in turn results in possiblefailure of bonding in this region. In actual practice strength ofadhesion to the metal surface is stronger than the strength ofthe adhesive itself. That means the joint will fail in midway ofadhesive instead of at the adhesive metal interface.Author prepared high-temperature organic adhesive by usingpreceramic polymer V-PMS as matrix, B4C powder and lowmelting point glass powder as additives, and is successfullyapplied to join Al2O3 ceramic. The obtained adhesiveexhibited outstanding heat-resistant property and bondingstrength. The results indicated that, up to 600 C, thepreceramic polymer and the glass additive play important rolein improving the bonding strength. Above 800 C, theoutstanding wetting property and chemical compatibility ofB2O3 formed by the oxidation of B4C are mainly responsiblefor the excellent high- temperature bonding strengths. [4]Literature ReviewResearcher presented the work on the strength and failureprediction of adhesive joints of brittle epoxy bonding of twodissimilar adherends, effects of bond thickness and scarf angleupon the strength of joints is addressed. The model forstrength prediction proposed is based on three parameters as,interface corner toughness, interfacial crack, fracturetoughness and interfacial toughness. It is reported that thestrength of adhesive joint reduces with increasing bondthickness and scarf angle. Also shear joint specimens havehigher reliability than butt and scarf joints. Although the stresssingularity order at interface corner is max. [5]The work of different researchers in the area of strengthanalysis of butt type adhesive joint is presented below,Author presented simple analytical formulae in literature toextract basic elastic material properties of adhesives subjectedto tensile loading. A numerical parameter study for differentcombinations of adherend/adhesive materials and butt-jointgeometries has been performed to investigate the influence ofThese parameters on the adhesive deformation. It is shownthat the shape of the deformed adhesive layer essentiallydepends on the specimen geometry and the material606

International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.comInternational Conference on Emerging Trends in Engineering, Technology and ArchitectureInvestigator followed the strategy previously developed formonotonic loadings. The crack initiation in adhesively bondedjoints is analyzed, under various tensile /compression-shearcyclic loadings using a modified Arcan device with a singlebonded joint designed to strongly limit stress concentrations.Experimental results, for a ductile adhesive, under cyclicloadings are presented for different load amplitudes and meanloads; they underline that the evolutions of viscousdeformations and of damage depend on the loading type. [6]Creating the 3D modelThe 3D model of the component is created in CATIA V5 R16environment as shown in Figure 2. The model is created intwo easy steps. First one plate is created and assignsAluminium or Mild Steel material to it. Then create thesecond plate and assign the Aluminium or Mild Steel materialto it. These materials will decide the variation of materialcombinations in joint.Adhesive BondingA. Advantages of adhesive joints:The various types of adhesive joints are widely used now daysin automobile and aerospace industries because of its inherentadvantages listed below.It is lightweight chemical, so reduces weight of the joint ascompare to riveted or bolted which adds its self weight tothe joint.Adhesivejoining techniques do not require holes, asriveted or bolted joints do, which can lead to stressconcentration.Adhesives are compressible in nature which helps to dampthe vibrations generated at high speed.Different types of adhesives for different applications areavailable commercially at very low cost.Some special types of adhesives are able to sustain at veryhigh temperature and varying environmental conditions.Figure 2: 3D model of the Metal PlateHypermesh 11.0 is opened in user profileTo open RADIOSS, click Start then HyperMesh. A UserProfiles window should pop up, as shown in Figure 3. If theUser Profiles window doesn’t pop up go to Preferences thenclick on User Profiles. Under the Application drop down listselect HyperMesh then select RADIOSS Bulk Data deckand click on OK.B. Case study of butt type metal to metal adhesive joint:Figure 1: Butt type tensile joint configuration.Figure 1 shows the butt type tensile joint configuration usedfor the strength analysis in simulation with RADIOSS. TheStructural Epoxy Adhesive is used to join two metal Plates.Table 1: Material PropertiesModulus of ElasticityMaterial Used(E) in MPaStructural Epoxy1.085e3Aluminium6.895e4Mild Steel2.100e5Figure 3: User Profile of HyperworksPoisson’sRatio (ν)0.380.330.30The 3D model is imported in HyperMeshTo import 3D model, go to File and click on Import. Then forthe Import Type choose Geometry and for the File typechoose Auto Detect. Then click the yellow folder icon andbrowse to where the CatPart file is located and click on Importthen Close. The imported geometry i.e. two plates will look asshown in Figure 4.The material properties of the metal plates i.e. Aluminium andMild Steel and the adhesive used i.e. Structural Epoxy are asshown in Table 1. Following is the detailed procedure adoptedfor the Finite Element Analysis.607

International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.comInternational Conference on Emerging Trends in Engineering, Technology and Architecturenodes on extreme left face of the red plate and apply an axialload on each node in Y direction. The model under constraintsis shown in Figure 7.Figure 4: Imported 3D model of the metal platesMesh the platesUse create-2D Automesh option to mesh both plates one byone, enter the following values to define the mesh.Element Size: 1.5Mesh Type: quadsClick on mesh button. A uniform mesh will be generated. Themeshed component will be seen as shown in Figure 5.Figure 7: Joint with Boundary ConditionsModel is checked and analysis is runAfter completing all boundary conditions and applying allloads, click on Analysis tab and save the file asAdhesive Joint.fem and click on Radioss. It will run thesolver file and displays that analysis is completed; the promptdisplay is shown in Figure 8.Figure 5: Meshed PlatesCreate adhesive connectorFor creating adhesive first of all hide one meshed plate thenselect some of the elements on end plate. Then click on elemsand select by face to select all elements on that face to join byadhesive. For components click on comps and select Plate 01and Plate 02. In type of connector select adhesives and enterthe value of density as 3 under (T1 T2)/2 options withtolerance of 10. An adhesive will be generated between thesetwo plates as shown in Figure 6.Figure 8: Solver Run promptView the resultsTo see the results click on Hyperview in Analysis tab. We willget the required results such as displacements and elementalstresses (Von-Mises and maximum shear stresses) inHyperview environment. Figure 9 shows the magnitude ofdisplacement for the joint of 1 mm adhesive thickness understatic tensile loading.Figure 6: Adhesive ConnectorFigure 9: Magnitude of DisplacementApply boundary conditionsNodes on extreme right face of the blue plate are selected, andconstrain their all degrees of freedom with a zero value. Thisconstrain comes under SPC load collector. Then select theNow following are the images which displaying the results forthe elemental stresses obtained at joint consisting of simpleVon Mises stresses in Figure 10 and simple maximum shearstresses in Figure 11.608