The present research evaluates the presence of damage, including delamination and cracks, affects the deflection response of an adhesively bonded single lap joint (SLJ). In this study, the numerical analysis is performed for intact and influence of different damages in the adherend of SLJ in the commercial simulation software (ABAQUS). The circular delamination of radius ‘R’ 10 mm and crack having length ‘l’ 20 mm, the radius of curvature ‘Rc’ 0.2 mm are imposed into the laminate adherend using node-to-surface interaction technique. The stability of the simulation model is verified by comparing the deflection values from published results and experimental data. The confirmed simulation model is broadened to examine the impact of design factors (fiber orientation, loading position, delamination shape, crack position and orientation, and delamination position with and without crack) on the deflection response for various overlapping lengths (25, 30, 35, and 40 mm) for final design recommendation. Additionally, the sensitivity analysis was performed using a surrogate model (i.e., variance-based method) by constructing the second-order polynomial function to quantify the influence of damages under the input parameters. The detailed features and multivariate model functions have been analysed for the various damage cases of SLJ.
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