This paper aims to investigate damage behavior and failure mechanism of adhesive-bonded Y-joints consisting of carbon fiber-reinforced polymer (CFRP) skins, PVC cores, and steel plates under three-point bending loading. Five three-point bending tests are adopted to study the load-bearing characteristic and damage mode of joint under different skin thicknesses and bending positions. Meanwhile, a procedure is developed to characterize the composite material failure by user-defined subroutine VUMAT, and numerical simulation is performed to reveal the flexural behavior and failure mechanism. Subsequently, structural optimization of the Y-joint is carried out in conjunction with ABAQUS-Isight, considering the thickness and lap length of CFRP skins. Reasonably good agreement is achieved when comparing the flexural behavior between experimental results and numerical predictions. These studies reveal that the bending load capacity of the Y-joint exhibits an increase with greater plate thickness, and the damage of plates and core is more serious when the bending location is near the core. Furthermore, the load-bearing capacity of Y-joint increases by 20.4% when the number of CFRP layers is 7 while the overlap lengths are 140 mm and 85 mm, respectively. This finding indicates that the optimized joint achieves a higher load-bearing capacity with a minor increase in mass.
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