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Spar Wingskin Joint (SWJ) comprises of a thin spar which overlaps and is co-cured to a thick wingskin by suitable adhesive materials. These joints are mostly used in integral modular fabrication of aircraft and fuselage wing structures usually made with curved laminated Fibre Reinforced Polymeric (FRP) composite panels. This paper deals with the analyses of initiation of adhesion failure and its propagation in SWJs subjected to transverse loadings using Finite Element Analyses (FEA) and fracture mechanics approach. Normal and shear stress distributions at different interfacial locations between the adherends and the adhesive have been evaluated. Tsai-Wu coupled stress failure criteria have been used to identify the location of onset of adhesion failure. The critical location for onset of adhesion failure has been found to be at the toe-end of the spar wingskin overlap region. Pre-embedded adhesion failure has been simulated at this location and Strain Energy Release Rate (SERR) components corresponding to Mode I, Mode II and Mode III of adhesion failure have been determined using the principle of Virtual Crack Closure Technique (VCCT). Rate of propagation of adhesion failure has been evaluated by sequential release of Multi-Point Constraint (MPC) and contact finite elements provided at the pre-embedded failure front. It has been observed that Mode I component of SERR primarily governs the process of adhesion failure propagation. The appropriate spar overlap length on the wingskin has been determined in order to prevent adhesion failure. Further, an attempt has been made to improve the structural integrity of the SWJ by reducing the stress concentration at the ends of spar and wingskin overlap. This has been achieved by obtaining a favourable stress distribution over the entire joint structure by using Functionally Graded Materials (FGM) in the spar and wingskin adherend instead of FRP composite panels. Exponential gradation indices have been used for material grading of the spar and wingskin adherends. It has been seen that peel and shear stresses and values of SERR components as well as total SERR reduce significantly by use of FGMs with suitable exponential material grading index. [ABSTRACT FROM AUTHOR]

3D Finite Element Analyses have been carried out for Spar Wingskin Joints made with laminated Graphite Fibre Reinforced Plastic composites subjected to uniformly distributed transverse load. The delamination has been pre-embedded at the most likely location, i.e. in resin layer between the top and next ply of the fibre reinforced plastic laminated wingskin and near the spar overlap end. Multi-Point Constraint finite elements have been made use of at the vicinity of the delamination fronts. This helps in simulating the growth of the embedded delamination at both ends. The inter-laminar peel and shear stresses responsible for causing delamination damage have been evaluated. Strain energy release rate components corresponding to the Mode I (opening), Mode II (sliding) and Mode III (tearing) of delamination are determined using the principle of Virtual Crack Closure Technique. These are seen to be different and non-self-similar at the two fronts of the embedded delamination. Mode I Strain energy release rate ( G I ) primarily governs the process of delamination propagation. [ABSTRACT FROM AUTHOR]

Adhesive bonding techniques have increased its application in automobile industries. The most common bonded joint configuration is the lap-shear joint, which when subjected to loading shows a differential substrate straining at the overlap ends. One of the methods to improve its performance is by introducing a reverse bent angle to the adherends at the overlap area. In this paper, the parameters which affect the strength of the reverse bend joints are found out by conducting experiments on different specimens. A detailed study was carried out showing the trends in the joint performance by varying the input parameters. Preformed angle at the overlap area, overlap length, ultimate tensile strength and modulus of the substrates have shown significant effect on the improvement of strength. For most of the adherends used in the automotive industries it has been found that a 10 degree preformed reverse bend joint consistently showed a 15 percent improvement in the strength compared to the traditional lap-shear joint. A model was developed based on Artificial Neural Networking system identification methods to predict the optimum joint configuration based on the given input parameters. This can be used to design high-performance adhesive bonded joints for parts and assemblies in automotive and aerospace industries. [ABSTRACT FROM AUTHOR]