Design and Optimization of Single Lap Hybrid Adhesive Joint in A Car Body

IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441
A Publisher for Research Motivation........
Volume 3, Issue 4, April 2015
Design and Optimization of Single Lap Hybrid

Adhesive joint in a Car Body
1.
Ketaki Sahastrabudhe, Prof.S.H.Deshmukh2

1
Ketaki Sahastrabudhe
2
Prof.S.H.Deshmukh
ABSTRACT
There are many types of joining techniques available which comes under permanent, semi-permanent or temporary category.
Due to enormous advantages the adhesive joining technique becomes popular now days. The research work carried out
highlights the significance of hybrid joint (i.e. dissimilar materials and two different types of adhesives) over the conventional
type of adhesive joint. Taguchi method is used to finalize the number of experiments to be carried out. . The results obtained in
the form of shear strength are used to further predict the full factorial 81 results and gives the optimum combination
i.e.A1B2C3D3. This combination is validated using confirmation test. Analysis of Variance (ANOVA) gives the contribution of
individual factor in the generation of shear strength and clearly shows that the combined use of E20HP and H3151 plays vital
role i.e. over 60%. The experimental results are further verified and validated by carrying out Finite Element Analysis (FEA).
1.INTRODUCTION
Adhesives can be found in most major components of the car interior including headliners, door panels, interior pillars,
instrument panels, seating and package trays. They are especially adept at laminating and assembling dissimilar
substrates. An example is the lamination of vinyl cover skin-to-polyurethane foam and attachment to an anti-lock
braking system (ABS) or polycarbonate (PC)/ABS instrument panel. Adhesives are also used to bond ductwork,
assemble Components, fasten graphics and attach carpet. [ 1]
Some of the advantages of using adhesives include the following:
Invisible bonding;
Even distribution of the bond stress;
Ability to join dissimilar substrates and surfaces;
Ability to fill gaps;
Elimination of vibration failure;
Corrosion protection;
Reduced manufacturing/assembly costs;
Bond strength.
2.EXPERIMENTATION
In this single lap jointtesting experiments E20HP and H3151 type structural adhesive are used. Hybrid joint i.e.
Aluminium and Glass epoxy material is used. Al 3003 grade and GE10 type is used for experiments. Joint preparation
is based on ASTM D1002 std. Adherend material thickness is 0.5,1.0 & 2.0mm is used. Lap length is 12.50, 18.75,
25mm is presents. Total length is 100mm & width is 25mmas per ASTM std.
Factors which affect the adhesive single lap joint: Adherend material combination (C)
type of adhesive used (D)
L27 array is used for joint preparation. Total 27 samples is prepare for testing with two repetitions. Joint sample testing
is done on UTM (STS-248 Model).
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Fig.01.Adhesive Used for experimentation
Fig.02.Model of Adhesively Bonded Single lap Joint

Table 1: Factor and Level Combinations
Adherend material test sample
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3.RESULT ANALYSIS
DoE as per Taguchi method using L27 orthogonal array for two repetitions as per the procedure discussed in early
following results / responses are obtained. After applying DoE we get the mean and S/N response .with the help of this
we get the optimum result of the experiments i.e. A1B2C3D3
Table 2: Response table
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With the help of contour plots we get the exact area of maximum shear stress.
Test result of confirmation test is as follows. This test specimen is prepare as per the optimum combination i.e. lap
length=12.5mm, adherend thickness =1mm, material=AL+GE, adhesive=E20+H3151.
4.FINITE ELEMENT ANALYSIS

The finite element method has evolved as a powerful tool in the analysis of engineering problems in various fields. FEA
of Single lap joint is modeled, meshing, static structure analysis and final result is done in ANSYS R15. In SLJ 2-D
nonlinear elastic element is used. 8 node rectangular isoperimetric element and Plane stress condition is considered
during analysis. For SLJ analysis CZM (cohesive zone modelling) approach is considered.
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Fig.06. Single Lap Joint as per ASTM D1002

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Fig.07. Meshed view of single lap joint
Total stress of lap joint:-To verify the reliability of the predicted results the confirmation test was carried out
5.CONCLUSION
It is clearly seen that the nature of the adhesive joint in terms of providing shear strength is scatter. The results
obtained from the tests shows the variability from 5 kN to 10 kN. It clearly signifies that there is a need of
standardizing the process parameter values.
From the Taguchi analysis using larger-the-better criterion, optimum combination obtained is A1B2C3D3. A1 =
Lap length 12.5 mm, B2 = Plate thickness 1 mm, C3 = AL+ GE and D4 = E20HP + H3151. The predicted value
for this combination is 11.97 kN.
REFERENCES
[1]. R.d.adams and j. ComynJoining using adhesives, Tutorial. Volume 20. Number 2. 2000. pp. 109117
[2]. SinaEbnesajjad, Adhesives Technology Handbook, 2nd Edition, William Andrew, USA, 2008
[3]. Pizzi and K. L. Mittal, Handbook of Adhesive Technology, 2nd Edition, Marcel and Dekker, New York, 2003
[4]. Shigleys Mechanical Engineering Design, Eighth Edition McGrawHill Primis ISBN: 0390764876
[5]. Bill Broughton, Measurement Good Practice Guide No. 28- Durability Performance of Adhesive Joints, NPL,
UK, ISSN 1368-6550, March
[6]. JinsengJhang, et. al, Effect of Surface Pretreatment on Adhesive Properties of Aluminium Alloys, Journal of
Material Science Technology, 24, pp.236-240, 2008.
[7]. DOT/FAA/AR-02/97, Shear Stress-Strain Data for Structural Adhesives, U.S. Department of Transportation,
November 2002
[8]. Hyonny Kim and Keith Edward, Stress Analysis of Adhesive Bonded Joints In-plane Shear Loading, Journal of
Adhesion, pp. 1-42 , 2001
[9]. DOT/FAA/AR-03/21, Characterization of In-Plane, Shear Loaded Adhesive Lap Joints: Experiments and
Analysis, U.S. Department of Transportation, May 2003
[10]. DOT/FAA/AR-05/12, Methods of Analysis and Failure Predictions for Adhesively Bonded Joints of Uniform and
Variable Bondline Thickness, U.S. Department of Transportation, May 2005
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[11]. K. E. Metzinger and T. R. Guess, How Geometric Details can affect the strength of adhesive lap joints,
American Institute of Aeronautics and Astronautics, pp. 1-9
[12]. Shiuh-ChuanHer, Stress analysis of adhesively bonded lap joints, Composite structures Journal, 47, pp. 673-678,
1999.
[13]. Jan Godzimirski and SlawomirTrackzuc, Numerical Calculations of Adhesive Joints Subjected to Shearing,
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[14]. L. Roy Xuet. al, An Experimental and Numerical Investigation of Adhesive Bonding Strengths of Polymer
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Letters, 58, pp. 3451-3456, 2004
[16]. Chien Chang Lin and Yee Shown Lin, A Finite Element Model of Single Lap Adhesively Joint, International
Journal of Solid Structures, 30(12) pp. 1679-1692, 1993
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Design and Optimization of Single Lap Hybrid Adhesive Joint in A Car Body

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IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

A Publisher for Research Motivation........

Volume 3, Issue 4, April 2015