EXPERIMENTAL EVALUATION AND FINITE ELEMENT ANALYSIS OF

GLASS FIBRE COMPOSITE HYBRID JOINTS

M.PremKumar1, G.mahesh2
1
, Assistant professor Department of Mechanical Engineering
Sree sakthi Engineering College, Coimbatore, India.
2
Professor, Department of Mechanical Engineering,
Sree sakthi Engineering college, Coimbatore, India.

ABSTRACT
Abstract: : The composite structural members are highly used in the following applications such as aerospace, automobiles,
robotic arms, architecture etc., has attracted extensive attention in the past decades. One of the important issues in the composite
technology is the repairing of aging of aircraft structures. In such applications and also for joining various composite parts together,
they are fastened together either using adhesive or mechanical fasteners. Modeling and static analysis of 3-D models of the joints
were carried out using ANSYS 11 FEA software. The results were interpreted in terms of Von Mises stress. A parametric study was
also conducted to compare the performance of the hybrid joint with varying adherent thickness, adhesive thickness and stress
distribution of these joints must be understood. ANSYS FEA tool has been performed to investigate the stress distribution
characteristics of various configuration of single lap joint. This study was focused on the analysis of stress distribution in three
prominent joining methods namely, bonded, riveted and hybrid joints. FEA is used to study the stress distribution in the members
involved under various design conditions and various joints failure criteria.
Keyword: Composite materials, hybrid joint, bonded joint, riveted joint, FEA-ANSYS 11

INTRODUCTION In the present project, an attempt is made to analyze the

Over the past three decades, application of composite
materials are continuously increasing from traditional
application area such as military aircraft, commercial aircraft
to various engineering fields including automobiles, robotic
arms and even architecture. Due to its superior properties,
composites have been one of the materials used for repairing
the existing structures. In such applications and also for
joining various composite parts together, they are fastened
together either using adhesive or mechanical fasteners.
Nowadays , a novel method call hybrid joint is also being
employed, when a combination of both adhesive and
mechanical fasteners is used. structural adhesive bonding is
one of the most used joined techniques in advanced structures
but,joint strength ,they bring in some issues, from the
technological bonded pieces have to be handled carefully
until a minimum strength has developed ,which may not be
feasible or rather complicated in the case of series production
Therefore, the combination of adhesive bonding with
other joining techniques could be a solution for that designer
who would like to use adhesive but who are concerned about
the use of the adhesive in the combination with fastening
gives the opportunity to obtain better performance in
comparison with the techniques
stress distribution in 3-D models of three configurations of
single lap joint, namely, bonded, riveted and hybrid joints. A
parametric study of hybrid joint, by varying the dimensional
parameter of the joint was also conducted.
MATERIALS AND METHODS
Modeling and static analysis of 3-D models of the joints(
bonded, riveted and hybrid) were carried out using ANSYS 11
FEA software. The results were interpreted in terms of Von
Mises stress. A parametric study was also conducted to
compare the performance of the hybrid joint with varying
adherent thickness, adherent thickness and overlap length.
Literature Review:
Chan, W.S ,S.Vedhagiri, “Analysis of composite
bonded/bolted joints used in repairing”
A proposed new design was incorporated into the
composite hybrid joint where two different types of
attachments were used in order to provide alternate load
paths to redirect load to the fastener and utilize the
fastener to provide strength to the joint once the joint
was loaded. Two types of attachments were used a
stepped attachment and a curved attachment.

the composite structural members are highly used in the

following applications
 Jin-Ha Park1 , Kang-Woo Jeong2 . Jin-Ho
Choi1
“A Study on Failure Strength Evaluation Of Hybrid
Composite Joint”.
As composites have become popular in recent
years, the design of the composite joint has become a
very important research area because the structural
efficiency of the composite structure is determined by
its joints, not by its basic structures. Generally, the
joining methods of the composite structures are
classified into mechanical and adhesive types. We
evaluated the failure strength of the hybrid joints
composed of an adhesive bond in conjunction with
mechanical fastening. The double lap joint jig was used
for the tensile test of the hybrid joint.
F.Avila , Plinio de O. Bueno
“An experimental and numerical study on adhesive
joints for composites “
This paper addresses the advantages and
disadvantages of the wavy-lap joint and design is
studied. To can able to guarantee the data consistency a
statistical study is performed considering not only the
sample size population but also the statistical
differences between the single-lap and wavy-lap points.
Besides, the experimental tests, a final element
simulation is carried out to analyze the stress fields
inside the joints. In addition, this stress field
distribution can also be the reason for the adherent
delamination observed on the wavy-lap joints. So far,
the modified wavy-lap joint seems to lead to stronger
joints
Jun Cao, Joachim L.Grenestedt
“Design and testing of joints for composite
sandwich/steel hybrid ship hulls”
The current research concentrates on hybrid ships,
consisting of an Advanced Double Hull Stainless Steel
center section, to which a composite material bow
and/or stem is attached. Two concepts of joints, a
bonded-bolted joint and a co-infused perforated joint,
were evaluated. Hybrid joint beam specimens were
manufactured and also tested: composite sandwich
beams, and steel references beams. The test result show
that both types of joints had excellent strengths,
approaching that of the composite sandwich reference
specimens.
B.Kolesnikov , L. Herbeck, A.
“CFRP/titanium hybrid material for improving
composite bolted joints”
This report displays experimental results
demonstrating the advantages influence of titanium
hybridization on specific characteristics of CFPR-
materials, thus proving the mechanical potential of
CFPR/titanium hybrid materials when used as an
advanced reinforcement technique for highly loaded
composite joints
C. O. Ryu, J. H. Choi and J. H. Kweon
“Failure Load Prediction of Composite Joints
using Linear Analysis”
.In this article, linear finite element analyses in
which the pin of the composite joint is assumed to be a
frictionless rigid body are performed and the failure
load of the mechanically fastened composite joint is
predicted by the failure area index (FAI) method. From
these analyses, it has been found that the FAI method
can predict the failure loads of composite joints to
within 20.1%.
J. H. Choi, Y. J. Chun. “Failure Load
Prediction of Mechanically Fastened Composite
Joint”
In this paper, a failure area index method is
proposed to predict failure loads of mechanically
fastened composite joints under plane stress condition
with the same stacking sequence. The suggested failure
area index method is shown to produce very favorable
comparisons with measured failure loads of
mechanically fastened composite joints with the
difference well within 10% for all 17 cases
investigated.
Sheppard, Kelly , Tong
“ A damage zone model for the failure analysis of
adhesively bonded joints”
A damage zone method based on 3D finite
element analysis was proposed to predict the failure
loads of single-lap bonded joints with dissimilar
composite-aluminum materials. Analysis also
considered the material nonlinearity of the aluminum
adherend due to the stress exceeding yield level. Based
on the experimental observation that the failure modes
of the specimens were dominated by delamination and
debonding, the Ye-criterion was applied to account for
the out-of-plane failure of composite adherend and the
Von Mises strain criterion was applied for the adhesive
layer. The failure indices were multiplied to the
predicted damage zone as a weight factor and the
calculated damage zones were divided by an area or
volume considering the joint geometry.
C. S Ban, Y. H. Lee, J. H. Choi and J. H. Kweon
“Strength prediction of adhesive joints using the
modified damage zone theory.
As fiber reinforced composites have been widely
used in aircraft and space structures, their joint design
has become a very important research area because
these joints are often the weakest parts of composite
structures. In this article, the failure load of a
mechanically fastened composite joint subjected to a
clamping force was tested and predicted using the
failure area index (FAI) method. The failure load of
composite joints subjected to clamping forces on
different geometric shapes and dimensions were
predicted using the FAI method, and the results were
compared with experimental results. From the tests and
analyses, the failure load of a mechanically fastened
composite joint subjected to a clamping force could be
predicted within 23% via the FAI method.
Balzani,w.Wawanger “Adhesive joints in
composite materials “In this paper a combined
numerical approach was presented for the determination
of mixed mode critical energy release rate of adhesive
joints in composite laminates.
K.N.Anyfantis,N.G.Tsouvalis “Experimental
parametric study of adhesive joints between dissimilar
adherents. The primary objective of the work is to
investigate the effect of various parameters. on the
failure load and failure mode of joints with dissimilar
materials.For the purpose,mild steel and carbon fiber
reinforced polymer laminates have been considered as
the structural adherent material
COMPOSITE JOINTS
limitations imposed by materials or the
manufacturing process, need for disassembly of
structure for transportation and access for
inspection and repair etc. Basically, there are two
types of load-carrying joints available.
Mechanically fastened joints and adhesively
bonded joints. Nowadays, a novel method called
hybrid joint is also being used in certain
applications. Bonded joints can be made by gluing
to pre-cured laminates together with the suitable
adhesives or by forming joints during the
manufacturing process, in which case the joint and
the laminate are cured at the same time (co-cured).
Here, load transfer between the substances take
place through a distribution of shear stress in the
adhesive Riveted joints can be used quite
successfully on laminated up to about 3 mm thick
and also where a tight fit, called interference fit, is
necessary. The choice lies between solid and
hollow types and whichever is chosen, care must
be taken to minimize damage to the laminate
during hole-drilling and closing of rivet (Mathew
and Rawlings, 1999). The holes create stress
concentration and reduce the strength of the
substrate laminates. Other than this, these joints
incur a large weight penalty and also create a
potential corrosion problem resulting from contact
with the composites. Also disassembly is not
possible in riveted joints. Hybrid joints have a
combination of adhesive bonding and mechanical
fasteners (Fu and Malick,2001). In the presence
case, rivet has been used as the mechanical
fastener. The advantages of using a combined
bonded-riveted design apply mainly in a repair
situation. It is generally accepted that a bonded
joint is stronger than a mechanically fastened joint Contact was defined between the laminate and the
and a well-designed bonded joint. rivet using TARRGE170 element for the target and
a 3-D non-linear contact element, CONTA174 for
Material properties of E-glass fibre
the contact, with a friction co-efficient of 0.2.
S.no Property E-Glass pretension section was designed at the mid portion
of the rivet.
1 Tensile Strength,Mpa 1400-3400
2 Elasticity Modulus, Gpa 72-76
3 Elongation to break % 3.0-4.5
4 Density g/cm3 2.54-2.63
5 Cost ratio 15
6 Poisson Ratio 0.3

Properties of redux 319

S.no Property Value

1 Young’s Modulus 2.8 Gpa
2 Poisson’s Ratio 0.4

Bonded joint Hybrid Joint

The composite laminates of FEA model for
bonded joints were developed by using Layered
46, a 3-D brick element. The adhesive layer was
modeled using SOLID-45, an 8-node brick
element. The adherent and adhesive were glued
together using Boolean operation. Finer mesh was
used in the design.
This model is similar the riveted joint, expect that
it has a thin layer of adhesive between the laminates.
The minimum value of stress was found to be 2.306 N
mm-2 and was located on the laminates and the rivet
head. The maximum value stress was found to be 15063
N mm-2 and was found to be in the adhesive layer near
the laminate-shank interface.

Riveted joints

The composite laminated were designed using

layered 46, a 3-D brick element. The rivet was
designed using SOLID-45, 8-node brick element.
The mesh was refined adjacent to the rivet-hole
and at the overlap ends. A neat fit was assumed
between the rivet and laminated in all simulations.
Boundary conditions and loads
The analysis for bonded joints was
performed by applying a tensile load of 5000 N at
the end of the joint which was free to move in the
longitudinal direction only (Ux=Uy=Uz=0). The
opposite end of the joint was fixed with boundary
condition (Ux=Uy=Uz=0). The analysis for riveted
and hybrid joints were performed in two steps.
First, a clamping load of 6kN was applied through The rivet head and the laminate surface take
the application of a pre-tension load at the mid- up less stress compared to the inferior of the
portion of the rivet. Secondaly, a tensile load of laminate and the rivet shank. The case of hybrid
5000 N was applied to the end of the joint had joint is found to have a situation that is in between
clamped with boundary conditions of bonded, that of both the above joints. The rivet shank and
riveted and hybrid joints. the adhesive layer are the main areas that have
maximum stress concentration. Thus, from the
Properties above observation, it was found that hybrid joint
can be used in a situation where riveted joint alone
S.no Properties Value
1 E1 138 Gpa is not sufficient to take up the entire load since it
2 E2 10 Gpa has characteristics in between the bonded and
3 E3 10 Gpa riveted joints. It is mainly applicable in repair
4 Y 0.3 Gpa situation. The study primarily considered stress
5 G12 7.2 Gpa distributions in the laminates and limited
6 G23 7.2 Gpa consideration was given to load transfer through
7 G21 7.2 Gpa the joint.

Design Parameter

S.no Parameter Value(mm)

1 Thickness of laminate 2.1
2 Adhesive 0.4
3 Overlap length 25
4 Width of laminate 25
5 Length of laminate 100
6 Rivet head diameter 4.96
7 Shaft diameter 3.1

Analysis

The stress was distributed throughout the

laminate and the adhesive took up much of the
load. The maximum stress is also low since the
applied load alone acts on the joint, whereas in
riveted joint, the maximum stress concentration
was very high since pre-tension load was also
applied to the joint.
 Novel solution of riveted joints

Modeling of joints

The analysis of the project was performed by applying a

tensile load of 5000N at the end of the joint which was free to
move in the longitudinal direction only (UY=UZ=0).the
opposite end of the joint had fixed boundary
condition(UX=UY=UZ=0).

Result and Discussion

The load distribution in revit,bonded and hybrid

joints was investigated experimentally using tensile test
and a three-Dimensional finite element model was
developed through use of finite element analysis .The
result from the experiment were found o be in good
agreement with those obtained from finite element
analysis.

Experimental Analysis

In bonded joints, the stress was distributed

throughout the laminate and the adhesive took up much
of the load. The maximum stress is also low since the
applied load alone acts on the joint, whereas in riveted
joint, the maximum stress concentration was very high
since pre-tension load was also applied to the joint. The
Revited joints rivet head and the laminate surface take up less stress
compared to the inferior of the laminate and the rivet
shank. The case of hybrid joint is found to have a
situation that is in between that of both the above joints.
The rivet shank and the adhesive layer are the main
areas that have maximum stress concentration. Thus,
from the above observation, it was found that hybrid
joint can be used in a situation where riveted joint alone
is not sufficient to take up the entire load since it has
characteristics in between the bonded and riveted joints.
It is mainly applicable in repair situation. The study
primarily considered stress distributions in the
Hybrid joint
laminates and limited consideration was given to load
transfer through the joint.

Load Parameters

S.no Joint type Ultimate Load

1 Rivet 1.730KN
2 Bonded 4.125
3 Hybrid 5.495
Riveted joints Experimental result

The result of ultimate tensile load for various

joints such as rivet, bonded and hybrid laminated
with the glass/Epoxy are described in the following
table.

S.no Joint type Ultimate Stress

Load Obtained(Mpa)
1 Rivet 1.730KN 3563.1
2 Bonded 4.125 842.69
3 Hybrid 5.495 790.7

PARAMETRIC STUDY

Bonded joints Geometric parameters in the joint were varied and

the stress distributions were compared to find the
efficiency of the joint as their geometrical parameters
are changed. This could be realized by profiling the
adherent’s layer thickness quadratic ally or linearly to
reduce or eliminated the shear stress concentration at
the ends. Joints with adherent’s layer thickness of 0.21
mm were compared using a constant overlap length of
25.4 mm and adhesive thickness of 0.4 mm. it was
found that as the number of layers decreases, the
maximum stress location shifted from the adherent
where the loaf was applied to the adhesive layer and
Hybrid joints then to the other adherent. Decreasing the adherent
layers also increases the level of shear stress in the
adhesive.

CONCLUSION

In the present study, FEA for the prediction of

stress distribution in bonded, riveted and hybrid
joints has been carried out. 3-D models were
created and analyzed using ANSYS FEA software.
Von Mises stress was used to compare the results.
Thus from the present study, it was found that a
well-designed hybrid joint is very when compared
to bonded or riveted joints in case of repair
situation in aircraft structures.
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