ETH Research Database

Project Summary
Maximum-Strength Design of Bonded Joints
1) Creation date of the summary: 09.10.2014
2) Record ID: 7654
3) Last update: 20.07.2012
4) Project status: Completed (12.06.2001 - 28.02.2009)
5) Organizational unit: Departement Maschinenbau und Verfahrenstechnik, Institut fr Mecha-
nische Systeme (IMES), Ermanni, Paolo, permanni@ethz.ch, LZ=03507
6) Project leader(s):
- Ermanni, Paolo, permanni@ethz.ch, Dep. Maschinenbau und Verfahrenstechnik, Inst. f.
Design, Mat. und Fabrikation
7) ETH researcher(s): no entry
8) External researcher(s): no entry
9) Funding source(s):
- Stiftungen
10) Partner organizations: no entry
11) Short Summary: Development and validation of numerical optimisation methods to design
optimum onserts
12) Keywords: Structural Mechanics
c ETH Zrich, all rights reserved. Last updated: 06.08.2004
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13) Project description:
Description
The onsert is a cost efcient element to realize selective load transfer in a single skin, e.g. alumi-
num sheet, continuous ber reinforced plastic laminate, or in a sandwich element. The advantage
of the onsert, as compared with the insert technology, is that the structure is not disturbed by a drill
hole. This means that stress concentrations, which may drastically impair both static and fatigue
strength, are avoided. The gure shows a demonstrator element which consists of the Algroup bus
prole system M5438, the alugrip system and a plastic sandwich-element (continuous glass ber
reinforced laminate skins with Airex foam core). The onsert-element is bonded on the laminate
with a special adhesion system which fullls the requirementof gap lling.
Methods
We want to achieve maximum-strength designs for onserts by studying the mechanisms that limit
the strength of bonded joints. From the mechanisms we will derive objective functions the mini-
mum of which result in maximum strength. These objective functions depend on shape parameter-
sof the link that have, via the structural properties of the link as well as the thicknessdistribution of
the bond layer, a direct inuence on the stress distribution within the bondand the sandwich. The
given multimaterial-sandwich parameters, in terms of geometry as well as material combination,
inuence the shape of the optimum link in a very complicated manner.This motivates the desire
for an automated design tool.
The optimization model uses, as objective function to be minimized, the standard deviation of
the von Mises stress in the bond from the inner to the outer edge of the onsert (one ofthe goals
of the project is to nd an objective function that is better suited for predictingbonding strength).
The optimization variables, generally, determine the shape of the onsert that has an inuence on
the stress distribution in the bond. The minimization method is based on gradient information. The
stresses occuring in the optimized maximum-strength design are much reduced compared to those
of the initial design.
Results and discussion
Our FORTRAN computer program ONSERT demonstrates the workings of our optimization ap-
proach. The structural model makes use of the assumed rotational symmetry of the considered
structures which are loaded in the axial direction only. The numerical representation of the model
is based on the nite-element method (FEM) and two-dimensional elements. The structural analy-
sis shows that the von-Mises stresses are generally unevenly distributed and, specically, perturbed
by stress singularities.
14) Popular description: no entry
15) Graphics:
Onsert Technology Demonstrator
c ETH Zrich, all rights reserved. Last updated: 06.08.2004
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Alcan Technology & Managament Neuhausen, Switzerland
16) Publications:
- Keller, D., Kress, G., Ermanni, P. 2007-06-11. Evolutionary Strength Optimization of On-
sert and Insert Shapes for Local Load Introduction. Proc. Evolutionary and Deterministic Methods
for Design Optimization and Control with Applications to Industrial and Societal Problems (Euro-
gen 2007), Jyvskyl, Finland.
- Keller, D.; Kress, G.; Ermanni, P. 2007-01-01. Strength-optimal onsert shapes. Composites
science and technology, Elsevier Science, (12/ 68), Amsterdam, 2376-2382.
- Kress, G. 1992. Width Inuence on Stiffness Measurements of Multidirektional CFRP La-
minates Under Uniaxial Load. Composites Engineering, Pergamon Press, (2/ 2), 83-90.
- Kress, G., Ermanni, P. 2005-03-31. Tragende Sandwichstrukturen dank Onsert Technik.
Adhsion, (4).
- Kress, G.; Ermanni, P. 2006-01-01. The Onsert, A New Joining Technology for Sandwich
Structures. Proc. Int. Conf. Buckling and Postbuckling Behavior of Composite Laminated Shell
Structures, Elsevier, Orlando.
- Kress, G., Fritsche D., and Ermanni P. 2005. Failure Criteria and Onsert Shape Optimizati-
on. International Journal of Adhesion & Adhesives, (2/ 25), Elsevier Ltd., 109-120.
- Kress, G.; Naeff, P.; Niedermeier, M.; Ermanni, P. 2006-01-01. The onsert, A new joining
technology for sandwich structures. Composite structures, Elsevier, (2/ 73), Kidlington, Elsevier,
196-207.
c ETH Zrich, all rights reserved. Last updated: 06.08.2004
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- Kress, G., P. Naeff, M. Niedermeier, P. Ermanni. 2004-04-30. Onsert Strength Design. In-
ternational Journal of Adhesion & Adhesives, (3/ 24), Elsevier Ltd., 201-209.
17) Links to important web pages:
- http://www.structures.ethz.ch
c ETH Zrich, all rights reserved. Last updated: 06.08.2004
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