Numerous advantages of the bonded joints result in wide application in the aircraft, motor industry or powertrain components. These types of joints enable joining materials with different mechanical properties (e.g. Stiffness) and dimensions without structure change. Proper joint design limits the field of local stress concentrations or even eliminates them. The structural integrity of complete structure depends on the fatigue estimation of the bonded joint. Application of the finite element method to life prediction of the double lap bonded joint metal-composite-metal is presented. Three dimensional numerical models are generated by professional engineering software tools. The contact problem is modelled between the epoxy resin and metal and composite surfaces. A laminated composite consists of the epoxy woven carbon prepreg. Elasto-plastic materials models of the adhesion and metal and orthotropy composite model allowed determining the contact normal stress in the interfaces in each deformation increment which is induced by an external load. MSC.Marc was used to determine the strain and stress distribution in the double lap bonded joint including contact normal stress in the steel/adhesive and laminated composite/adhesive interfaces. Two numerical models of the double lap bonded joint were compared. The use of the presented method is more suitable for structure optimisation than numerical analysis.
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