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........ Email: [email protected]

Volume 3, Issue 4, April 2015 ISSN 2321-6441

Volume 3, Issue 4, April 2015 Page 10

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.A1 B 2C 3 D 3 . 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).

Design and Optimization of Single Lap Hybrid

Adhesive joint in a Car Body1.Ketaki Sahastrabudhe, Prof.S.H.Deshmukh

2

1Ketaki Sahastrabudhe

2Prof.S.H.Deshmukh







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







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 thiswe get the optimum result of the experiments i.e. A1B2C3D3

Table 2: Response table







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 ANSYSR

15. In SLJ 2-Dnonlinear 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.







Fig.06. Single Lap Joint as per ASTM D1002 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.

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R.d.adams and j. Comyn“Joining using adhesives”, Tutorial. Volume 20. Number 2. 2000. pp. 109±117

[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].

Shigley’s Mechanical Engineering Design, Eighth Edition McGraw−Hill Primis ISBN: 0−390−76487−6

[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

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[7]. DOT/FAA/AR-02/97, “Shear Stress-Strain Data for Structural Adhesives”, U.S. Department of Transportation,

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[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

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[11].

K. E. Metzinger and T. R. Guess, “How Geometric Details can affect the strength of adhesive lap joints”,

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[12].

Shiuh-ChuanHer, “Stress analysis of adhesively bonded lap joints”, Composite structures Journal, 47, pp. 673-678,

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[13].

Jan Godzimirski and SlawomirTrackzuc, “Numerical Calculations of Adhesive Joints Subjected to Shearing”,Journal of Theoretical and Applied Mechanics, 45(2), pp. 311-324, 2007

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Materials”, International Journal of Adhesion and Adhesives, 24, pp. 455-460, 2004

[15].

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Letters, 58, pp. 3451-3456, 2004

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Documents

Design and Optimization of Single Lap Hybrid Adhesive joint in a Car Body