Fatigue performance and life estimation of automotive adhesive joints using a fracture mechanics approach

Chen, Qiuren; Guo, Hao; Avery, Katherine; Su, Xuming; Kang, Hong Tae

doi:10.1016/j.engfracmech.2017.01.005

Cited by 40 publications

(4 citation statements)

References 22 publications

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“…Adhesive bonding is particularly suitable for joining dissimilar materials without adding significant weight (compared to mechanical joints), achieving good fatigue resistance and providing design flexibility. 9–14 Nevertheless, joining multi-materials can be challenging. For this application, the mechanical behaviour under fatigue loading and the environmental resistance of adhesive joints needs to be studied in order to guarantee safety and reliability.…”

Section: Adhesive-bonded Joint Designmentioning

confidence: 99%

A vision for a lightweight railway wheelset of the future

Bruni

Mistry

Johnson

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part F:

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Rail vehicle lightweighting using fibre reinforced polymer composite materials is essential for the future of rail. This is recognised as a means of reducing carbon dioxide production through lower energy consumption, as well as reducing the impact on track degradation, thus delivering improved rail capacity and performance. This paper presents an overview of the work conducted within work package three of the NEXTGEAR project focused on the ‘wheelset of the future’. Three concepts for a hybrid metallic-composite railway axle are proposed and their strengths and weaknesses are assessed. A finite element analysis on the selected concept was conducted, including a solution for the bonded joints of the metallic collars which provide the interface to the wheels and bearings. An axle mass reduction of over 63% was shown. An overview is also provided regarding the analysis of manufacturability of the axle, non-destructive methods for axle inspection/structural health monitoring and effects of impacts from ballast stones. Finally, a preliminary evaluation of the benefits arising from the reduction of the unsprung masses is provided, based on multibody simulations of vehicle dynamics.

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Section: Adhesive-bonded Joint Designmentioning

confidence: 99%

A vision for a lightweight railway wheelset of the future

Bruni

Mistry

Johnson

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part F:

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“… t l is the thickness of the substrates. F l and M l are the line force and line moment applied on the l th layer substrate in FE models (Figure 8), calculated through the structural load method 3 . l = 1, 2 for the upper and lower debonded substrates, respectively, and l = 3 for the joined side.…”

Section: Total Fatigue Life Evaluationmentioning

confidence: 99%

“…The outstanding mechanical properties of adhesive‐bonded joints, for example, lightweight, uniform stress distribution, watertight, excellent corrosion protection, 1 enhanced noise, vibration and harshness (NVH) performance, 2 and the ability to join different materials, 3,4 lead to increasing use in joining complex auto body structures 5 . From the durability design's perspective, 6 there is a specific need for analysis and design tools that can provide physical insight and characterize the effects of design variables.…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical evaluations on the effects of adhesive fillet, overlap length and unbonded area in adhesive‐bonded joints

Lai

et al. 2020

Fatigue Fract Eng Mat Struct

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To realize robust structural design, the effects of the adhesive fillet, overlap length and unbonded area in adhesive‐bonded joints need to be fully understood and incorporated into a fatigue life estimation method. In the present work, both static and fatigue experiments are performed on six types of adhesive‐bonded joints to illuminate these effects systematically. A straightforward total fatigue life evaluation method is proposed to address these effects. A statistical crack initiation model is established based on the fatigue data of bulk adhesive specimens. Growth life is calculated using the interfacial crack model and mixed mode crack growth method. Good correlation is observed between the calculated and experimental fatigue lives. Furthermore, the effects of the adhesive fillet, overlap length and unbonded area are analysed based on both calculated and experimental results. Results indicate that adhesive fillet postpones crack initiation by reducing local strain level, both overlap length and unbonded area change the growth life by length. Besides, overlap length promotes the fraction of mode II strain energy release rate in total, reducing crack growth rates and extending growth life.

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“…[ 2 , 3 ]. However, adhesion has the advantages of fatigue resistance, good sealing and vibration reduction [ 4 ] and can also resolve the electrochemical corrosion problem in the connection of dissimilar materials [ 5 ]. In recent years, adhesion technology has increasingly been used to replace the traditional bonding process for the connection of rail train materials, which plays a very important role in the body structure connection.…”

Section: Introductionmentioning

confidence: 99%

Influence of Temperature, Humidity and Load Coupling on Mechanical Properties of Adhesive Joints and Establishment of Creep Model

Tan¹,

Zhou²,

et al. 2023

Polymers

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To study the creep and property degradation behavior of adhesive joints under the coupling action of temperature, humidity and load, polyurethane shear joints were prepared and tested. Different static loads were applied to joints at high temperature (80 °C) and high temperature and humidity (80 °C/95% RH) to test and analyze the creep deformation, and a suitable creep model was established. At the same time, the performance degradation test of the joints under the effect of multifactor coupling was carried out to obtain the variation law of the failure load, and the failure mechanism was discussed based on the failure section. The research shows that the creep strain of the joint at high temperature and humidity was significantly larger than that at high temperature, and the failure fracture time was shorter, in which water molecules played a role of softening and hydrolysis. The viscoelastic multi-integral creep model was used to analyze and predict the creep behavior of the joints. It was found that the creep model could better describe the creep behavior of the joints under uniaxial constant loading. Under the coupling effect of temperature, humidity and load, the failure load decreased with time, and with the increase in static load, the decline range and rate of failure load increased. It was found that the mechanical properties in the high temperature and humidity environment decreased significantly more than those in the high temperature environment. When a static load was applied during creep, cracks easily occurred inside the adhesive layer, and water molecules easily diffused inside the cracks, which increased the decay rate of the mechanical properties. This study provides good theoretical significance and engineering value for the application of polyurethane adhesion structures in rail vehicles.

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Fatigue performance and life estimation of automotive adhesive joints using a fracture mechanics approach

Cited by 40 publications

References 22 publications

A vision for a lightweight railway wheelset of the future

A vision for a lightweight railway wheelset of the future

Experimental and numerical evaluations on the effects of adhesive fillet, overlap length and unbonded area in adhesive‐bonded joints

Influence of Temperature, Humidity and Load Coupling on Mechanical Properties of Adhesive Joints and Establishment of Creep Model

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