Laboratory Report

Simulation Laboratory (20MEMDPCSL)

Submitted to

Visvesvaraya Technological University

Jnana Sangama, Belgaum

in partial fulfillment of the requirements of

Master of Technology in Machine Design

By

Narayana.Addanki
USN : 1BM21MMD07

Post Graduate Studies and Research Centre

Department of Mechanical Engineering

B. M. S. COLLEGE OF ENGINEERING
(An Autonomous Institution under VTU)
PB 1908, Bull Temple Road, Bengaluru – 560 019.

September 2022

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 Department of Mechanical Engineering

Certificate

Certified that this Laboratory Report is a bonafide work carried out by Mr.
Narayana.Addanki (1BM21MMD07), in partial fulfillment of requirements of
Second Semester Simulation Laboratory (20MEMDPCSL – Lab Component) for
the award of Master of Technology in Machine Design of the Visvesvaraya
Technological University, Belgaum, during the year 2021-22. It is certified that all
corrections / suggestions indicated for internal assessment have been incorporated
in the report deposited in the departmental library. The laboratory report has been
approved as it satisfies the academic requirements prescribed for the said degree.

Signature of Faculty-in-charge Signature of HOD

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 CONTENTS

Sl. Page
Name of Experiment
No. No.
Lab Experiment-7(Adhesive Bonded Joints analysis using
1. ANSYS) 4 to 24

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 Lab Experiment-7
Adhesive Bonded Joints Analysis using ANSYS
1. Introduction
Adhesive bonded joints are an excellent alternative to mechanical fasteners
and in some cases, it might be the only solution. Adhesive joints offer high
strength to weight ratio, in particular for joints in shear. Here are some
advantages
Advantages:
a. Weight Reduction. High strength to weight ratio.
b. Reduced number of production parts, design simplification.
c. The need for milling, machining & forming operations is reduced.
d. Large area bonds can be made with a minimum workforce without special
skills.
e. Roughly three times the shearing force of riveted or spot-welded joints.
f. Used as a seal and or corrosion preventer when joining incompatible
adherents.
g. Excellent electrical & thermal insulation.
h. Superior fatigue resistance. Three times that of riveted & spot-welded
joints.
i. The flexibility of adhesives allows for the variation in CTE’s when joining
dissimilar materials.
j. Stress concentration as in mechanical joints is eliminated.
When two plates (substrates) are bonded by an adhesive, we have essentially
two types of forces at play:
Adhesion: This is the force of connection between adhesive and substrate.
Adhesion keeps the adhesive bonded to the substrate.
Cohesion: This is the force of connection within the adhesive itself. It is
basically the material strength of the adhesive material after it has cured.

Bonded Joint fails in the following modes of failure:

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The cohesive failure mode is essentially failure (due to fracture or yield) of
the adhesive material. The adhesive failure is basically the separation of
adhesive from the substrate leaving a clean surface. Next, we have a mixed
failure mode which can be cohesive and adhesive failure modes combined.
Finally, the substrate itself can fail under load. In analysing a bonded joint
we make the following assumption:
Substrate failure mode can be avoided by redesigning the substrate structure.
Adhesive and mixed failure modes can be avoided by carefully preparing the
surface to be bonded by means of priming and or other surface preparation
guidelines provided by the adhesive supplier.
If we can ensure that substrate and adhesive failure modes don’t happen then
we are able to fully leverage adhesive strength properties and design for
cohesive failure. Furthermore, cohesive failure can happen due to the
following types of loads:
Peeling Load: This type of load is applied normal to the adhesive bond Line
or adhesion surface and thereby tends to separate the two plates apart.
Shearing Load: This type of load tends to slide the plates parallel to each
other causing shear of adhesive material.
The typical peel strength of a bonded connection using epoxy adhesive is ~
60 psi compared to ~ 2000 psi in shear. Therefore adhesively bonded joints
are not ideal for tension connections which can cause peeling to happen.
Bolts are ideal for tension joints whereas bonded joints work best in
connections in shear loading.

2. Analytical Models
2.1 VOLKERSEN
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The first analytical method known in literature for the stress analysis of
bonded joints was developed by (Volkersen,1938). Volkersen method, also
known as the shear-lag model, introduced the concept of differential shear.
The bending effect caused by the eccentric load path is not considered. The
adhesive shear stress distribution τ is given by:

The reciprocal of ω has units of length and is the characteristic shear-lag

distance, a measure of how quickly the load is transferred from one adherend
to the other. tt is the top adherend thickness, tb is the bottom adherend
thickness, ta is the adhesive thickness, b is the bonded area width, l is the
bonded area length, E is the adherend modulus, Ga is the adhesive shear
modulus and P is the force applied to the inner adherend. The origin of x is
the middle of the overlap and is shown in Fig. 1.

Eq. (1) shows that for a joint with different adherends the adhesive stress is
maximum (and thus failure most likely) at the overlap end where the loaded
adherend is thinnest. This principle is shown in Fig. 2, for tt >> tb

Further, the lowest adhesive stresses are obtained when the adherends are
identical, tt = tb = t. Assuming that the joint is sufficiently long such that
sinh(ωl) = cosh(ωl) , Eq. (1) will result in:
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This is an extremely useful formula which shows a number of very important
features about the size of the peak
adhesive stress in a single overlap joint:
For long joints it is independent of the joint length.
It increases with increasing adhesive shear modulus.
It increases with decreasing adherend modulus and thickness and adhesive
thickness.
2.2 GOLAND & REISSNER
(Goland and Reissner, 1944) were the first to consider the effects due to
rotation of the adherends, Fig. 3. They divided the problem into two parts:
(a) determination of the loads at the edges of the joints, using the finite
deflection theory of cylindrically bent plates and (b) determination of joints
stresses due to the applied loads.

The adhesive shear stress distribution τ found by Goland & Reissner is given
by:

where, P is the applied tensile load per unit width, c is half of the overlap
length, t is the adherend thickness, ν is Poisson’s ratio and k is the bending
moment factor:

2.3 HART-SMITH
In contrast with (Volkersen, 1938) or (Goland and Reissner, 1944), (Hart-
Smith, 1973) considered adhesive plasticity.In the report presented for the
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NASA they analyzed both, the single lap joint (SLJ) and the double lap joint
(DLJ). For both analyses they combined elastic peel stress with plastic shear
stresses. According to (Hart-Smith, 1973), the adhesive elastic shear stress
distribution τ(x) is given by:

The shear plastic stress was modeled using a bi-linear elastic-perfectly

plastic approximation. The overlap is divided into three regions, a central
elastic region of length l and two outer plastic regions. Coordinates x and x’
are defined as shown in Fig. 4.

2.4 OJALVO & EIDINOFF

(Ojalvo and Eidinoff, 1978) model is based (Goland and Reissner, 1944)
model. They modified some coefficients in the shear stress equations by
adding new terms in the differential equation and considering new boundary
conditions for bond peel stress calculation. Their leading work was the first
in predicting the variation of shear stress through the bond thickness. The

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adhesive nondimensional shear stress τ* distribution found by (Ojalvo and
Eidinoff, 1978) is given by:

3.Methodology
Finite element analysis is used for Adhesively bonded single lap joint under
axial tension force is shown in Fig 5. Joint geometry, physical dimensions,
and loading of the problem for stress analysis is also indicated in the same
figure. In fact, distributions of the stress components are not uniform across
the width[y-axis]. With these considerations, a three-dimensional model is
considered in the work So, variations of the stresses along the width are
investigated. The materials are assumed as isotropic and homogenous
aluminum. Adhesive is also modeled as an isotropic material. Mechanical
properties of selected material are given in Table 1.

Fig.5 Geometry Details and boundary condition of the Model

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 Table 1. Material properties of the model

4.Problem Statements
Performing the Adhesive joint, joint configuration and failure Analysis using
Ansys.
5.Aim of Experiment
Stress and strain distributions in the adhesive bonded joints subjected to
Axial force is investigated using Ansys.
6.Geometric Model Details is shown in Fig.6

Fig.6 Geometry Details of Model

7. Finite Element Modelling
The modelling of any finite element problem includes generally five steps;
a) Defining the material properties of the model,
b) Creating the geometry of the model.
c) Discretizing the model into number of finite elements (i.e., meshing of the
geometry).
d) Applying boundary and loading conditions.
e) Solving the problem for its subsequent results.

8.Ansys Report
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Units
TABLE 2
Unit System Metric (mm, kg, N, s, mV, mA) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (A4)
TABLE 3
Model (A4) > Geometry Imports
Geometry
Object Name
Imports
State Solved

TABLE 4
Model (A4) > Geometry Imports > Geometry Import (A3)
Object Name Geometry Import (A3)
State Solved
Definition
Source F:\adhesion\adhesive_files\dp0\SYS\DM\SYS.agdb
Type DesignModeler
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies Yes
Parameters Independent
Parameter Key
Attributes Yes
Attribute Key
Named Selections Yes
Named Selection Key
Material Properties Yes
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems Yes
Coordinate System Key
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update Yes
Compare Parts On Update No
Compare Parts Tolerance Tight
Analysis Type 3-D
Mixed Import Resolution None
Import Facet Quality Source
Clean Bodies On Import No
Stitch Surfaces On Import None
Stitch Tolerance 0.0000001
Decompose Disjoint Geometry Yes

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 Enclosure and Symmetry Processing Yes

Geometry
TABLE 5
Model (A4) > Geometry
Object Name Geometry
State Fully Defined
Definition
Source F:\adhesion\adhesive_files\dp0\SYS\DM\SYS.agdb
Type DesignModeler
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 25.4 mm
Length Y 3.49 mm
Length Z 190.5 mm
Properties
Volume 8441.9 mm³
Mass 2.3161e-002 kg
Scale Factor Value 1.
Statistics
Bodies 3
Active Bodies 3
Nodes 62966
Elements 10946
Mesh Metric None
Update Options
Assign Default Material No
Basic Geometry Options
Parameters Independent
Parameter Key
Attributes Yes
Attribute Key
Named Selections Yes
Named Selection Key
Material Properties Yes
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems Yes
Coordinate System Key
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update Yes
Compare Parts On Update No
Analysis Type 3-D
Import Facet Quality Source
Clean Bodies On Import No
Stitch Surfaces On Import None
Decompose Disjoint Geometry Yes

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 Enclosure and Symmetry Processing Yes

TABLE 6
Model (A4) > Geometry > Parts
Object Name Solid Solid Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Treatment None
Material
Assignment araldite Aluminum Alloy
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 25.4 mm
Length Y 0.25 mm 1.62 mm
Length Z 12.7 mm 101.6 mm
Properties
Volume 80.645 mm³ 4180.6 mm³
Mass 0. kg 1.158e-002 kg
Centroid X 4.2738e-016 mm 2.6381e-016 mm 0. mm
Centroid Y -0.935 mm -1.87 mm 0. mm
Centroid Z -44.45 mm -88.9 mm 0. mm
Moment of Inertia Ip1 0. kg·mm² 9.9641 kg·mm²
Moment of Inertia Ip2 0. kg·mm² 10.584 kg·mm²
Moment of Inertia Ip3 0. kg·mm² 0.62513 kg·mm²
Statistics
Nodes 2564 30201
Elements 338 5304
Mesh Metric None

FIGURE 7
Model (A4) > Geometry > Image

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 TABLE 7
Model (A4) > Materials
Object Name Materials
State Fully Defined
Statistics
Materials 3
Material
0
Assignments

Coordinate Systems
TABLE 8
Model (A4) > Coordinate Systems > Coordinate System
Global Coordinate
Object Name
System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. mm
Origin Y 0. mm
Origin Z 0. mm
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]

Connections
TABLE 9
Model (A4) > Connections
Object Name Connections
State Fully Defined

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 Auto Detection
Generate Automatic Connection On Refresh Yes
Transparency
Enabled Yes

TABLE 10
Model (A4) > Connections > Contacts
Object Name Contacts
State Fully Defined
Definition
Connection Type Contact
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Auto Detection
Tolerance Type Slider
Tolerance Slider 0.
Tolerance Value 0.48054 mm
Use Range No
Face/Face Yes
Face-Face Angle
75. °
Tolerance
Face Overlap Tolerance Off
Cylindrical Faces Include
Face/Edge No
Edge/Edge No
Priority Include All
Group By Bodies
Search Across Bodies
Statistics
Connections 3
Active Connections 3

TABLE 11
Model (A4) > Connections > Contacts > Contact Regions
Contact Contact Region Contact Region
Object Name
Region 2 3
State Fully Defined
Scope
Scoping Method Geometry Selection
Contact 1 Face
Target 1 Face
Contact Bodies Solid
Target Bodies Solid
Protected No
Definition
Type Bonded
Scope Mode Automatic
Behavior Program Controlled
Trim Contact Program Controlled
Trim Tolerance 0.48054 mm

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 Suppressed No
Advanced
Formulation Program Controlled
Small Sliding Program Controlled
Detection Method Program Controlled
Penetration Tolerance Program Controlled
Elastic Slip Tolerance Program Controlled
Normal Stiffness Program Controlled
Update Stiffness Program Controlled
Pinball Region Program Controlled
Geometric Modification
Contact Geometry Correction None
Target Geometry Correction None

Mesh
TABLE 12
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Display Style Use Geometry Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Center Coarse
Initial Size Seed Assembly
Bounding Box Diagonal 192.22 mm
Average Surface Area 656.1 mm²
Minimum Edge Length 0.25 mm
Quality
Check Mesh Quality Yes, Errors
Error Limits Aggressive Mechanical
Target Element Quality Default (5.e-002)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No

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 Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 62966
Elements 10946

TABLE 13
Model (A4) > Mesh > Mesh Controls
Object Name Body Sizing
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 3 Bodies
Definition
Suppressed No
Type Element Size
Element Size 1.0 mm
Advanced
Defeature Size Default
Behavior Soft

FIGURE 8
Model (A4) > Mesh > Image

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Static Structural (A5)
TABLE 14
Model (A4) > Analysis
Static Structural
Object Name
(A5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
Environment Temperature 22. °C
Generate Input Only No

TABLE 15
Model (A4) > Static Structural (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Off
Solver Pivot Checking Program Controlled
Large Deflection Off
Inertia Relief Off
Quasi-Static Solution Off
Rotordynamics Controls
Coriolis Effect Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Combine Restart Files Program Controlled
Nonlinear Controls
Newton-Raphson Option Program Controlled
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Program Controlled
Advanced
Inverse Option No
Contact Split (DMP) Off
Output Controls
Stress Yes
Surface Stress No

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 Back Stress No
Strain Yes
Contact Data Yes
Nonlinear Data No
Nodal Forces No
Volume and Energy Yes
Euler Angles Yes
General Miscellaneous No
Contact Miscellaneous No
Store Results At All Time Points
Result File Compression Program Controlled
Analysis Data Management
Solver Files Directory F:\adhesion\adhesive_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files Directory
Save MAPDL db No
Contact Summary Program Controlled
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System nmm

TABLE 16
Model (A4) > Static Structural (A5) > Loads
Fixed
Object Name Force Force 2
Support
State Fully Defined Suppressed Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Face
Definition
Type Force Fixed Support
Define By Components  
Applied By Surface Effect  
Coordinate
Global Coordinate System  
System
X Component 0. N (ramped)  
Y Component 0. N (ramped)  
Z Component -3000. N (ramped) 3000. N (ramped)  
Suppressed No Yes No

FIGURE 9
Model (A4) > Static Structural (A5) > Force

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 FIGURE 10
Model (A4) > Static Structural (A5) > Force > Image

FIGURE 11
Model (A4) > Static Structural (A5) > Force 2

FIGURE 12
Model (A4) > Static Structural (A5) > Fixed Support > Image

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Solution (A6)
TABLE 17
Model (A4) > Static Structural (A5) > Solution
Solution
Object Name
(A6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done
MAPDL Elapsed Time 19. s
MAPDL Memory Used 1.6592 GB
MAPDL Result File Size 14.313 MB
Post Processing
Beam Section Results No
On Demand Stress/Strain No

TABLE 18
Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information
Solution
Object Name
Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Identify Element Violations 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility
Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

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 TABLE 19
Model (A4) > Static Structural (A5) > Solution (A6) > Results
Total Equivalent Elastic
Object Name Equivalent Stress
Deformation Strain
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Total Equivalent (von-Mises) Equivalent Elastic
Type
Deformation Stress Strain
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Results
Minimum 0. mm 1.2411 MPa 1.7924e-005 mm/mm
Maximum 113.36 mm 638.12 MPa 4.4329e-002 mm/mm
Average 43.944 mm 179.14 MPa 2.8019e-003 mm/mm
Minimum Occurs On Solid
Maximum Occurs On Solid
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1
Integration Point Results
Display Option   Averaged
Average Across
  No
Bodies

TABLE 20
Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation
Time [s] Minimum [mm] Maximum [mm] Average [mm]
1. 0. 113.36 43.944

FIGURE 13
Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation > Image

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 TABLE 21
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress
Time [s] Minimum [MPa] Maximum [MPa] Average [MPa]
1. 1.2411 638.12 179.14

FIGURE 14
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress > Image

TABLE 22
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Elastic Strain
Maximum
Time [s] Minimum [mm/mm] Average [mm/mm]
[mm/mm]
1. 1.7924e-005 4.4329e-002 2.8019e-003

FIGURE 15
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Elastic Strain > Image

Material Data
araldite
TABLE 23
araldite > Color

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 Gree
Red Blue
n
155 244 255

TABLE 24
araldite > Tensile Yield Strength
Tensile Yield Strength MPa
36490

TABLE 25
araldite > Isotropic Elasticity
Young's Modulus Poisson's Bulk Modulus Shear Modulus
Temperature C
MPa Ratio MPa MPa
3500 0.34 3645.8 1306

Aluminum Alloy
TABLE 26
Aluminum Alloy > Constants
Density 2.77e-006 kg mm^-3
Coefficient of Thermal Expansion 2.3e-005 C^-1
Specific Heat 8.75e+005 mJ kg^-1 C^-1

TABLE 27
Aluminum Alloy > Color
Gree
Red Blue
n
138 104 46

TABLE 28
Aluminum Alloy > Compressive Ultimate Strength
Compressive Ultimate Strength MPa
0

TABLE 29
Aluminum Alloy > Compressive Yield Strength
Compressive Yield Strength MPa
280

TABLE 30
Aluminum Alloy > Tensile Yield Strength
Tensile Yield Strength MPa
280

TABLE 31
Aluminum Alloy > Tensile Ultimate Strength
Tensile Ultimate Strength MPa
310

TABLE 32
Aluminum Alloy > Isotropic Secant Coefficient of Thermal Expansion
Zero-Thermal-Strain Reference Temperature C
22

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 TABLE 33
Aluminum Alloy > Isotropic Thermal Conductivity
Thermal Conductivity W mm^-1 C^-1 Temperature C
0.114 -100
0.144 0
0.165 100
0.175 200

TABLE 34
Aluminum Alloy > S-N Curve
Alternating Stress MPa Cycles R-Ratio
275.8 1700 -1
241.3 5000 -1
206.8 34000 -1
172.4 1.4e+005 -1
137.9 8.e+005 -1
117.2 2.4e+006 -1
89.63 5.5e+007 -1
82.74 1.e+008 -1
170.6 50000 -0.5
139.6 3.5e+005 -0.5
108.6 3.7e+006 -0.5
87.91 1.4e+007 -0.5
77.57 5.e+007 -0.5
72.39 1.e+008 -0.5
144.8 50000 0
120.7 1.9e+005 0
103.4 1.3e+006 0
93.08 4.4e+006 0
86.18 1.2e+007 0
72.39 1.e+008 0
74.12 3.e+005 0.5
70.67 1.5e+006 0.5
66.36 1.2e+007 0.5
62.05 1.e+008 0.5

TABLE 35
Aluminum Alloy > Isotropic Resistivity
Resistivity ohm
Temperature C
mm
2.43e-005 0
2.67e-005 20
3.63e-005 100

TABLE 36
Aluminum Alloy > Isotropic Elasticity
Young's Modulus Poisson's Bulk Modulus Shear Modulus
Temperature C
MPa Ratio MPa MPa
71000 0.33 69608 26692

TABLE 37
Aluminum Alloy > Isotropic Relative Permeability

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 Relative Permeability
1

9. Conclusions
The results are used to understating Stress and strain distributions in the
adhesive bonded joints subjected to axial force using Ansys.

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