Abstract
The research explores the effects of various geometric modifications on stress profiles within the adhesive layer of a single lap joint. The effects were numerically investigated by using the commercially available finite element code ABAQUS. Aerospace-grade aluminum alloy 6061-T6 adherends were bonded with Araldite 2011 adhesive. Geometric techniques ranging to external taper, internal taper, adherend rounding, adhesive fillets, and a combination of internal taper with adhesive fillet were examined. Optimum parameter of each geometric configuration was evaluated by following a parametric methodology. The best-performing parameter of each geometric configuration was then compared with the others for the reduction in peak peel and shear stresses. The reduction in peak stresses aims to increase the joint strength of lap joins by reducing the stress concentration points, hence delaying the crack initiation and propagation. The geometric configuration of internal taper with adhesive fillet showed the highest reduction in both peel and shear stresses of 88.58% and 39%, respectively, when compared to base geometry without any modification.
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