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Chapter 7:
Constructions Suitable for Adhesive
bonding
Source: Wikipedia
Agenda
Introduction
Constructional Examples
2
Introductional Example
Parameter
Mass of the car 1200 kg
Diameter of the 30 cm (≙ 0,3 m)
Bond
Necessary bond wanted
strength
Formula
Bond strength
Force
Circular area
3
Parameters that Influence the Strength
Adhesive Bond
• Adhesion properties
• Inner strength
Geometrical
design of the Material
bond seam
Strength of the bond • Surface properties
• Adherent thickness • Stiffness
• Adhesive layer • Mechanical properties
thickness
Stress
• Operating conditions
Suitable • Type of stress
construction (mechanical, ...)
Outer Load
...affect...
Building
Bauteil
Element
...reacts with...
Tensions Distortions
Source: vgl. www.mp.haw-hamburg.de 6
Agenda
Introduction
Design of Adhesive
Constructional Examples
7
Types of Stress
Mechanical Stress
● Static: material is under stationary, constant load
● Dynamic: material under temporarily changing load
Environmental Influences
● Humidity
● Heat
● Chemical reaction
8
Mechanical Types of Stress
Static Stress Dynamic Stress
Compressive Stress
Split Stress
● Should be avoided as it leads to high
linear stress
Peel Stress
● Should be avoided as it leads to high
linear stress
Source: www.seyffer-gmbh.de 13
Agenda
Introduction
Constructional Examples
14
Evaluation of Adhesive Bonds
Goal:
● Technical and economical optimised construction
● Quantitative verification of stress resistance and durability
● Minimising of the necessary effort for physical tests
Approaches to Calculation:
● Nominal tension
● Analytical Methods
● Numerical methods (i.e. finite elements method)
Source: www.fast.kit.edu/ 15
Nominal tension (1)
Basic Principle:
● σ= (current tension)
● σ < σzul (current tension < safe tension)
● Reduction factors take account of boundary conditions
σ: Occuring Tension
σzul: Permissable Tension
Tension Analysis:
σB: Breaking Tension
F: Force
A: Cross-Section
(static) (dynamic)
Aerf: Necessary Cross-Section
Dimensioning: ν: Security Factor
If the „real“ expected strength factors deviate strongly from the „ideal“ ones,
then the reduction factor is small (minimally 0)
If the „ideal“ expected strength factors are close to the „real“ ones, then the
reduction factor is big (maximum 1)
20
Reduction Factors (3)
The reduction factor is composed of many individual factors:
A = AA x AW x Alü x Ad x AD x AT x Awa x AM x Ast x Agesch x Adyn x Az x Aalt
● From:
● Results:
● Thus:
Principle:
● Decomposition of building element that is to be examined into small elements
● From the elemental solution, the solution for the entire system is derived
● Continuity conditions and equilibrium conditions at junction points are taken into
consideration
Result: An approximate solution for the entire system is derived from the
system of equations and its solution
28
Finite Elements Method (FEM) (3)
2. Set-up and separation of the FE-system
– Calculation of the stiffness relation between the elements
29
Finite Elements Method (FEM) (4)
3. Postprocessing
– Calculation of expansion and tensions within the elements
– Graphic evaluation
30
Finite Element Method in Bonding Technologies
Allows the exact calculation of stress distribution in adhesive bonds
Is only valid for newly joined bonds, not for aged adhesive bonds
● Reasons:
– There are no material principles that describe the material and adhesion
Source: www.sciencedirect.com 32
Finite Element Method in Bonding Technologies –
Example (2)
Depiction of the stress distribution in the adhesive bond
x [mm]
Quelle: TC Kleben 33
Agenda
Introduction
Constructional Examples
34
Design of Adhesive Bonds
These factors (amongst others) should be considered when designing
adhesive bonds:
● thickness of adhesive layer influences the bond strength
● no proportional relation between transferable force and overlap length
optimal balance between overlap length and adhesive layer thickness is necessary
35
Influence of the Adhesive Layer Thickness (1)
In shear testing, if all other conditions stay the same, the strength of a
bond depends on the thickness of the adhesive layer
Source: www.leitfaden.klebstoffe.com 36
Influence of the Adhesive Layer Thickness (2)
lÜ
2 3
1
1 2 3
overlap length [mm]
____ : real stress distribution
Introduction
Constructional Examples
41
Constructional Examples
Increase of bonding area
● Flat material
● Round material
● Hub-shaft-connections
Mounting:
● Chamfering of joint elements (angle ≈ 30°)
● Bonding area is in the force line Source: www.konstruktionsatlas.de 43
Constructional Design – Increase of Bonding Area
(Round Material)
Butt joint:
● Bonding at the front surfaces
● Mostly small bonding areas
Pin:
● Increase of bonding area through pin
● Information: Drill a hole in the blind hole for ventilation!
Source: www.konstruktionsatlas.de 44
Constructional Design – Increase of Bonding Area (Hub-
Shaft-Connections)
Hub-Shaft-Connection
● Bonding of disc on shaft
● Mostly small bonding area
Rings:
● Increase of bonding area with additional rings
Source: www.konstruktionsatlas.de 45
Constructional Design – Peel Stress (Overlapping) (1)
Overlap Bond:
● Peel stress at transition point to other buillding element
● Poor utilisation of the bond area
Increase of Area
● Reduce peel stress by increasing the bonding area and
reducing stiffness at the same time
Source: www.konstruktionsatlas.de 46
Constructional Design – Peel Stress (Overlapping) (2)
Support through formed sheets
● Relief of bonding area with the help of formed sheets
Source: www.konstruktionsatlas.de 47
Constructive Design – Peel Stress (Butt Joint Stress)
Butt angle impact
● Oppositioning forces create unfavorable peel stresses at the
bond
Relief Flap:
● Relief of critical areas with a flat material
● Flap takes forces as its position is in the force line
Source: www.konstruktionsatlas.de 48
Constructional Design – Stress Peaks (1)
Occurance of boundary stress peaks
building
element 2
building
element 1
Source: www.konstruktionsatlas.de 52
Rules of Design for Adhesive Bonds
Joint areas must fit to each other
Joint elements have to be fixated to each other during curing
Tensile and peel stress should be avoided, shear stress is better
Force transmission should be taken into account
Same thermal expansion of the parts
Bond areas should be dimensioned sufficiently
53