Journal of Adhesion Science and Technology

This article was downloaded by: [University of North Carolina]
On: 12 November 2014, At: 10:16

Publisher: Taylor & Francis
Informa Ltd Registered in England and Wales Registered Number: 1072954
Registered office: Mortimer House, 37-41 Mortimer Street, London W1T
3JH, UK
Journal of Adhesion Science

and Technology
Publication details, including instructions for
authors and subscription information:
http://www.tandfonline.com/loi/tast20
Stress analysis and strength

evaluation of single-lap
adhesive joints combined with
rivets under external bending
moments
a b
Jiemin Liu & Toshiyuki Sawa
a
Department of Aeronautical Engineering,
Shenyang Institute of Aeronautical Engineering, 52,
Huanghe Northern Street, Shenyang 110036, China
b
Department of Mechanical Engineering,
Yamanashi University, 4-3-11, Takeda, Kofu,
Yamanashi 400-8511, Japan
Published online: 02 Apr 2012.
To cite this article: Jiemin Liu & Toshiyuki Sawa (2001) Stress analysis and strength
evaluation of single-lap adhesive joints combined with rivets under external
bending moments , Journal of Adhesion Science and Technology, 15:1, 43-61, DOI:
10.1163/156856101743300
To link to this article: http://dx.doi.org/10.1163/156856101743300
PLEASE SCROLL DOWN FOR ARTICLE
Taylor & Francis makes every effort to ensure the accuracy of all
the information (the “Content”) contained in the publications on our
platform. However, Taylor & Francis, our agents, and our licensors
make no representations or warranties whatsoever as to the accuracy,
completeness, or suitability for any purpose of the Content. Any opinions
and views expressed in this publication are the opinions and views of
the authors, and are not the views of or endorsed by Taylor & Francis.
The accuracy of the Content should not be relied upon and should be
independently verified with primary sources of information. Taylor and
Francis shall not be liable for any losses, actions, claims, proceedings,
demands, costs, expenses, damages, and other liabilities whatsoever
or howsoever caused arising directly or indirectly in connection with, in
relation to or arising out of the use of the Content.
This article may be used for research, teaching, and private study
purposes. Any substantial or systematic reproduction, redistribution,
reselling, loan, sub-licensing, systematic supply, or distribution in any form
to anyone is expressly forbidden. Terms & Conditions of access and use can
Downloaded by [University of North Carolina] at 10:16 12 November 2014
be found at http://www.tandfonline.com/page/terms-and-conditions
J. Adhesion Sci. Technol., Vol. 15, No. 1, pp. 43– 61 (2001)
Ó VSP 2001.
Stress analysis and strength evaluation of single-lap

adhesive joints combined with rivets under external
bending moments
JIEMIN LIU 1 and TOSHIYUKI SAWA 2;¤

1 Department of Aeronautical Engineering, Shenyang Institute of
Aeronautical Engineering,
52, Huanghe Northern Street, Shenyang 110036, China
2 Department of Mechanical Engineering, Yamanashi University, 4-3-11, Takeda, Kofu,
Yamanashi 400-8511, Japan
Received in nal form 6 July 2000
Abstract—Stress analysis and strength evaluation of single-lap adhesive joints combined with rivets
(i.e. single-lap riveted-adhesive joints) under external bending moments are investigated by three-
dimensional nite element analysis (FEA). In this analysis, the effects of the ratio of Young’s moduli
of the rivets to that of the adherends and the initial tightening force produced in the process of
tting the rivets on the stress distributions at the interfaces between the adherends and the adhesives
are examined. The rupture process of single-lap riveted-adhesive joints is demonstrated through
simulating three debonded cases. Experiments to measure the strengths of single-lap riveted-adhesive
joints, single-lap riveted joints, and single-lap adhesive joints were carried out. The following results
were obtained: (1) for thinner adherends, riveted-adhesive joints, riveted joints, and adhesive joints
were of the same strength; (2) of the three types of joints, the strength of single-lap riveted-adhesive
joints was the greatest and that of single-lap riveted joints was the lowest in the case of thicker
adherends; (3) the predicted strengths coincided with the experimental results.
Keywords: Contact stress analysis; combination joints; tightening force; single-lap riveted-adhesive
joints; three-dimensional elasto-plastic nite element method; joint strength; strength evaluation;
maximum principal strain criterion.
1. INTRODUCTION
Single-lap adhesive joints have been widely used in mechanical, automotive, and
aerospace structures, as well as in the wood and plastics industries, because of the
enhanced performance of adhesives. Many investigations have been carried out on
the stress and deformation of single-lap adhesive joints [1 –9]. However, single-
¤
To whom correspondence should be addressed. E-mail: sawa@ccn.yamanashi.ac.jp
44 J. Liu and T. Sawa
lap adhesive joints have not been used as loading elements in structures because
the variation in the joint strength is substantial and the joint strength is relatively
small. One of the causes of the low joint strength is the singular stresses occurring
at the ends of the interfaces between the adherends and the adhesive. The rupture
of the joint will be initiated at the ends of the interfaces [7 – 14]. Thus, adhesive
joints combining adhesives with other mechanical fastening elements (bolts, rivets,
welding, etc.) have been developed [15, 16]. The objectives of joints combining an
adhesive with other fastening elements (combination joints) are to increase the joint
strength and to design joints from a fail-safe standpoint.
In this paper, the stress and strength of single-lap adhesive-riveted joints (com-
bination joints) under external bending moments are investigated both analytically
and experimentally. For comparisons of the joint strength and failure mode, single-
lap adhesive joints (without rivets) and single-lap riveted joints (without adhesive)
are also examined. In this study, the effects of the ratio of Young’s moduli of the
rivets to that of the adherends, the rivet initial tightening force, and the rivet loca-
tions on the interface stress distributions are examined. The rivet tightening force
produced in the process of tting the rivets is evaluated by the method proposed in
this paper. Rupture tests for measuring the strengths of the three types of single-lap
joints were conducted. The FEA results are compared with the experimental results.
2. FINITE ELEMENT ANALYSIS

A three-dimensional linear-elastic nite element analysis (E-FEA) and elasto-
plastic nite element analysis (EP-FEA) for the three types of single-lap joints
under external bending moments were carried out. Element 7 of MARC code was
used for the calculations [17]. Element 7 is an eight-node isoparametric arbitrary
hexahedral. As a trilinear interpolation function is used in this element, the strains
tend to be constant throughout the element. This results in a poor representation of
the bending behavior. In this analysis, the bending characteristics are improved by
using alternative interpolation functions [17]. Since the effect of the size of elements
near the interfaces, especially in the vicinity of the edges of interfaces, is critical on
the analytical results, the meshes are re ned near the interfaces. Figure 1 illustrates
a single-lap adhesive joint combining two rivets under an external bending moment.
In the riveted-adhesive joint, two rivets are tted after the two adherends are bonded
by an adhesive. The length, width, and height of the upper adherend are designated
as 2l1 , 2B, and 2h1 , and its Young’s modulus and Poisson’s ratio as E1 and º1 ,
respectively. Those of the adhesive are designated as 2l2 , 2B, 2h2 , E2 , and º2 .
The lower adherend is the same as the upper adherend in material and dimensions.
Young’s modulus and Poisson’s ratio of the rivets are denoted as Er and ºr . Figure 1b
shows the dimensions and locations of the rivets. The locations of the rivets are
described by 2lr , i.e. the distances between the centers of the rivets. The diameters
of the rivet, rivet hole, and rivet head are denoted as 2a, 2b, and 2c, respectively.
Thus, the distance between the hole wall and the outer diameter of the rivet can be
Single-lap adhesive joints combined with rivets 45
(a)
(b)
Figure 1. (a) Single-lap riveted-adhesivejoint with two rivets subjected to external bending moments.
(b) Dimensions and positions of the rivets.
expressed by b ¡ a, the contact length at the surfaces between the rivet heads and
the adherends in the radial direction by c ¡ b, and the thickness of the rivet head
by tr . The wall thickness of rivets is denoted as ±r .
Figure 2a shows a model for the FEA of a single-lap riveted-adhesive joint with
two rivets under external bending moments. Assuming that the stress distributions
due to an external bending moment acting on the left end-surface and the right end-
surface are linear in the z-direction, the external bending moment, M, is expressed
(a)
(b)
Figure 2. (a) Model for the FEA of a single-lap riveted-adhesive joint with two rivets (unit: mm).
(b) Example of the mesh division of a single-lap riveted-adhesivejoint with 6 mm adherend thickness.
by
4h21 B
MD p; (1)
3
where 2B D 25 mm. The p value is the maximum value of the stress distribution
at the ends (z D §h1 ). Due to the symmetry of the joint, only one half of the
joint is analyzed. The model shown in Fig. 2a can be used to analyze single-
lap riveted-adhesive joints with different adherend thicknesses by changing the
adherend thickness 2h1 to 1.6, 3, and 6 mm. The model shown in Fig. 2 can also
be used to analyze single-lap riveted joints and adhesive joints by replacing the
adhesive layer and two rivets. Figure 2b shows an example of the mesh division of
a single-lap riveted-adhesive joint with 6 mm adherend thickness.
The effects of the rivet tightening force, Young’s modulus of the rivets, and
the rivet locations on the interface stress distributions in the joints are examined
(Section 4.1).
3. EXPERIMENTS TO MEASURE THE JOINT STRENGTHS
3.1. Preparation of the specimens

In this study, experiments to measure the strength of single-lap riveted-adhesive
joints, single-lap adhesive joints, and single-lap riveted joints were carried out for
veri cation of the analysis. The adherends were made of mild steel (SS400, Japan
Industrial Standard) and the adhesive used was epoxy resin. Blind rivets (NSA4-2,
NSA4-4, NSA4-8) made of aluminum (A5154, JIS) were used for tting single-lap
adhesive joints with different adherend thicknesses. Table 1 shows the properties
of the materials used in the experiments. The widths of all the adherends, 2B,
were 25 mm. Three different adherend thicknesses, 2h1 , i.e. 1.6, 3, and 6 mm,
were chosen. Three types of specimens, single-lap riveted-adhesive joints, single-
lap riveted joints, and single-lap adhesive joints, were prepared for each adherend
thickness. The experiments were carried out on two types of riveted joints. One type
was prepared with two rivets which were tted near the ends of the lapped section
as shown in Fig. 2a (lr = l2 D 0:68), and the other with one rivet which was tted at
the middle point of the lap section (lr = l2 D 0). Joints are expressed as ‘Tt -N -C’,
where Tt indicates the adherend thickness, N the rivet number, and C the joining
method. C is described as b (bonded) or n (non-bonded). For example, the symbol
for a single-lap riveted-adhesive joint of 6 mm adherend thickness with two rivets
is T6 -2-b.
A surface degreasing procedure was used to prepare the adherend surfaces for
bonding. The bonded surfaces of the adherends were ground by sandpaper and
degreased by butanone. After that, the adherends were bonded using the epoxy
resin. Once the joints were bonded, the rivets were tted by a hand-riveter. A
correct tting method enhances the tightening force. The tting process of a rivet
Table 1.
Mechanical properties of the materials used in the rupture tests
Adherend Adhesive Rivet

(SS400) (EA9430) (A5154)
E (GPa) 200.4 1.770 71
º 0.291 0.370 0.3
¾y (MPa) 424.7 30.38 185
¾u (MPa) 647.7 34.42 280
"u 0.013 0.141
E: Young’s modulus; º: Poisson’s ratio; ¾y : yield stress; ¾ u : ultimate stress; "u :

ultimate strain.
in the single-lap adhesive joint can be described as follows. When the shaft head
is placed into the ange made from aluminum, a rivet head is formed and it will
contact the adherends as the pull force is exerted. Once the rivet head contacts
the adherends completely, the pull force P should be removed in order to release
the strain energy in the ange and the adherends. Then the pull force is exerted
slowly until the shaft is broken when the pull force is equal to the ultimate strength
of the shaft. After the shaft is broken, the tightening force occurs in the rivet (i.e.
in the ange). The tightening force is dif cult to determine exactly because large
elasto-plastic deformation and slip-contact phenomena take place during the tting
process. After tting, the single-lap adhesive joints with rivets were cured in an
oven at 60 ± C for 2 h and at room temperature for 24 h.
3.2. Determination of the rivet tightening force, Fr

Figure 3 shows a sketch for determining the tightening force, Fr . Figure 3a
corresponds to a complete contact state in which neither deformation nor stress
occurs in the adherends and rivets. Figure 3b shows a critical state at which the shaft
is subjected to the force Pu (the ultimate strength of the shaft). It is assumed that in
the tting process, the axial force Pry in the rivet keeps a constant compressive load,
which is given by
Pry D ¾ryAr ; (2)
where ¾ry is the yield stress of the rivet and Ar is the cross-sectional area of the
rivet. Thus, the contact force between the adherends and the rivet head, Pa , can be
expressed by
Pa D Pu ¡ Pry : (3)
The equivalent compressive deformation of the joint, 1, can be expressed by
1 D Pa =ka D .Pu ¡ Pry /=ka ; (4)
where ka is the equivalent stiffness constant of the joint system.
Figure 3c describes a deformation state at which the external force has been re-
moved completely. The deformation compliance condition of the joint is expressed
Figure 3. Sketch for determining the rivet tightening force, Fr .

Table 2.
Equivalent stiffness constants kr , ka and tightening force Fr for the riveted-adhesive
joints. Thickness of adhesive .2h1 / D 0:1 mm
2h 1 (D 2h3 ) ka kr Fr
(mm) (kN / mm) (kN/ mm) (kN)
1.6 496 105 0.189
3.0 502 75 0.136
6.0 541 51 0.092
by the following equation:
1 D 1a C 1r or 1 D Fr =kr C Fa =ka ; (5)
where 1a is the equivalent compressive deformation of the joint, and 1r and kr are
the tensile deformation and equivalent stiffness constant of the rivet, respectively.
Substituting equation (5) into equation (4) and considering the equilibrium condi-
tion Fr D Fa , the tightening force in the rivets is given by
Fr D [kr =.ka C kr /].Pu ¡ Pry /: (6)
It should be pointed out that the deformation (the amount of compressive

deformation) between the contact surfaces of the adherends with the rivet is the
average of the deformations of all points on the contact surfaces. All of them can be
determined by FEA. The method for determining the equivalent stiffness constants
of the adherends (including the adhesive) and rivets, ka and kr , is shown in the
Appendix. Table 2 gives ka , kr , and the rivet tightening force Fr . It can be seen
that as the thickness of the adherends increases, the equivalent stiffness constant of
the adherends, ka , increases, while the equivalent stiffness constant of the rivet, kr ,
decreases. The rivet tightening force Fr decreases because the stiffness constant of
the rivet is reduced.
3.3. Measurement of the joint strengths
Figure 4 shows a schematic diagram of the experimental set-up for single-lap

riveted-adhesive joints with two rivets. The dimensions and positions of the rivets
are the same as those in Fig. 1b. The total lap length is 25 mm. The two rivets are
tted at positions 4 mm from the ends of the lapped section. The distances between
the centers of the rivets, 2lr , is 17 mm. The out-diameter (2a ) and the wall thickness
(±r ) of the rivets are 3.2 and 0.7 mm, respectively. The diameter of the rivet holes
(2b) is 3.4 mm, and that of the rivet heads (2c) 6.4 mm. By applying a lateral force
W , which was measured by a load cell, a bending moment of M D W=2 £ 40 is
applied.
Figure 4. Schematic diagram of the apparatus used in the rupture tests (unit: mm).
4. ANALYTICAL RESULTS AND COMPARISON WITH THE EXPERIMENTAL

ONES
4.1. Effect of the rivet tightening force Fr on the interface stress distributions
Figure 5 shows the distributions of the normalized peel stress ¾z =¾r at the interfaces
between the upper adherend and the adhesive (¡l2 6 x2 6 l2 , z2 D h2 , y D 0)
for the single-lap riveted-adhesive joint shown in Fig. 2a. In Fig. 5, the solid line
shows the result for a single-lap adhesive joint in which no rivet is tted under
an external bending moment M. The dotted line shows the result for a single-lap
riveted-adhesive joint combining two rivets under an external bending moment M
only. The long and short dashed lines show the result for the case where two rivets
are tted in a single-lap adhesive joint under both an external bending moment M
and a tightening force Fr . When both the external bending moment M and the
tightening force Fr are exerted on the joint at the same time, the tensile stress ¾r
caused by Fr is assumed to be equal to the maximum bending stress ¾a produced by
M, as shown in Fig. 2a. Assuming that simple tensile theory and engineering beam
theory are applicable, the stresses ¾r and ¾a can be expressed as follows:
¾r D Fr =Ar ; (7)
¾a D 3M=.4Bh21 /: (8)
Equating the stresses as ¾r D ¾a, the relationship between the external bending
moment M and the tightening force Fr can be expressed by
3Ar
Fr D M; (9)
4Bh21
where Ar is the cross-sectional area of the rivet.
From Fig. 5 it is seen that the singular stress at the left edge of the interface
of a single-lap riveted-adhesive joint is the same as that of a single-lap adhesive
Figure 5. Distributions of the normalized peel stress ¾ z=¾r at the interface (¡l2 6 x2 6 ¡lr ¡ b,
y2 D 0, z2 D h 2 ). 2l2 D 25 mm; 2lr D 17 mm; 2b D 3:4 mm; 2a D 3:2 mm; 2c D 6:4 mm;
2h2 D 0:1 mm; 2h1 D 1:6 mm; E 1 D 70 GPa; º1 D 0:3; E2 D 1:75 GPa; º2 D 0:37; Er D 71 GPa;
ºr D 0:3. ‘No rivets’ corresponds to a single-lap adhesive joint subjected to a bending moment
M. ‘Moment M’ corresponds to a single-lap riveted-adhesive joint with two rivets subjected only to
bending moment M. ‘M and Fr ’ corresponds to a single-lap riveted-adhesive joint with two rivets
subjected to both bending moment M and tightening force Fr .
joint in the case of no-tightening force. When the tightening force Fr occurs in the
rivets, a compressive stress near the rivet holes exists between the two adherends.
Thus, the nal rupture strength of the single-lap riveted-adhesive joints will be
increased. However, it is noted that the peel stress at the edge of the upper interface
is enhanced, contrary to expectations. The additional peel stress caused by the initial
tightening force will reduce the initial rupture strength of the joints. Therefore, it is
important to reduce this additional peel stress caused by the initial tightening force
as much possible.
4.2. Effect of the ratio Er =E 1 of the rivet Young’s modulus to the adherend Young’s
modulus on the interface peel stress distributions
In order to reduce the additional peel stress at the left edge of the interface caused
by the initial tightening force, it is necessary to investigate the effect of the rivet
stiffness on the interface stress distributions. Figure 6 shows the distribution of
the peel stress ¾z at the interface between the upper adherend and the adhesive
(¡l2 6 x2 6 ¡lr C b, z2 D h2 , y D 0) when a tightening force Fr occurs in a single-
lap riveted-adhesive joint as shown in Fig. 2a. Young’s modulus E1 and Poisson’s
ratio º1 of the adherends are chosen as 70 GPa and 0.3, respectively; those of the
adhesive, E2 and º2 , are 1.77 GPa and 0.37, respectively. The values of Er =E1 , the
ratio of Young’s modulus of the rivets to that of the adherends, are chosen as 1 / 3,
Figure 6. Effect of Young’s modulus ratio E r =E1 on the normalized peel stress ¾ z =¾r at the interface
(¡l2 6 x2 6 ¡lr ¡ b, y2 D 0, z2 D h2 ). 2l2 D 25 mm; 2lr D 17 mm; 2b D 3:4 mm; 2a D 3:2 mm;
2c D 6:4 mm; 2h2 D 0:1 mm; 2h1 D 6 mm; E1 D 70 GPa; º1 D 0:3; E 2 D 1:75 GPa; º2 D 0:37,
Er D 71 GPa; ºr D 0:3.
1, and 3. In Fig. 6, it can be seen that the peel stress at the edge of the interface is
reduced as the value of Er =E1 increases. Thus, rivets with a higher Young’s modulus
are recommended for use in the design of single-lap riveted-adhesive joints.
4.3. Effect of the location of the rivets on stress distributions at the interface
Figure 7 shows the effect of the positions of the rivets on the maximum principal
stress ¾1 at the upper interface (¡l2 6 x2 6 l2 , z2 D h2 , y2 D 0). The positions
of the rivets are de ned by the ratio lr = l2 . In the case of lr = l2 D 0, a single rivet
is used and it is located at the middle point of the lap section (x2 D 0). The dotted
line shows the interface stress distribution in the case of lr = l2 D 0:68. The case
of lr = l2 D 1 corresponds to a single-lap adhesive joint with no rivets. In Fig. 7,
it can be seen that the effect of the rivets on the singular stresses in the vicinity of
the left edge of the upper interface will be reduced as the rivets are moved towards
the middle point of the lap section. When a rivet is tted at the middle point, the
magnitude of singular stresses in the vicinity of the edges of the upper interface is
the same as that of a single-lap adhesive joint. It can be concluded that if the rivets
are tted near the edges of the lapped section, the joint strength will be enhanced.
However, if the rivets are tted near the middle point of the lapped section, the joint
strength will not be enhanced.
Figure 7. Effect of the positions of the rivets on the normalized maximum principal stress ¾ 1 =¾r at
the interface (¡l2 6 x2 6 l2 , y2 D 0, z2 D h2 ). 2l2 D 25 mm; 2b D 3:4 mm, 2a D 3:2 mm;
2c D 6:4 mm; 2h2 D 0:1 mm; 2h1 D 6 mm; E 1 D 70 GPa; º1 D 0:3; E2 D 1:75 GPa; º2 D 0:37;
Er D 71 GPa; ºr D 0:3.
Figure 8. Stress distributions at the interface (¡l2 6 x2 6 ¡lr ¡ b, y2 D 0, z2 D h 2 ). 2l2 D 25 mm;

2lr D 17 mm; 2b D 3:4 mm; 2a D 3:2 mm; 2c D 6:4 mm; 2h 2 D 0:1 mm; 2h 1 D 6 mm;
E1 D 200:4 GPa; º1 D 0:291; E2 D 1:77 GPa; º2 D 0:37; Er D 71 GPa; ºr D 0:3.
4.4. Stress distributions at the adhesive interface

Figure 8 shows the distributions of the maximum principal stress ¾1 and each stress
component ¾x , ¾y , ¾z and ôxz at the adhesive interface of a single-lap riveted-
adhesive joint of 6 mm adherend thickness with two rivets under an external bending
moment of 27 kN mm and a tightening force of 92 N (this value is evaluated by the
method described in Section 4.2). Because the shear stresses ¿xy and ¿yz are too
Figure 9. Stress distributionsat the interface along the left rivet hole (x2 D ¡lr Cb cos µ , y2 D b sin µ ,
0 6 µ 6 ¼ , z2 D h 2 ). 2l2 D 25 mm; 2lr D 17 mm; 2b D 3:4 mm; 2a D 3:2 mm; 2c D 6:4 mm;
2h2 D 0:1 mm; 2h 1 D 6 mm; E1 D 200:4 GPa; º1 D 0:291; E2 D 1:77 GPa; º2 D 0:37,
Er D 71 GPa; ºr D 0:3. Stress unit: MPa.
small compared with the stresses ¾1 , ¾x , ¾y , ¾z and ¿xz , they are not shown in Fig. 8.
The dimensions of the joint are the same as those shown in Fig. 2a. The mechanical
properties of the adherends, adhesive, and rivets are the same as those used in the
experiments (see Table 1).
Figure 9 shows the distributions of the stresses ¾1 , ¾x , ¾y , ¾z and ¿xz at the
interface along the rivet hole (x2 D ¡8:5 C 1:7 cos µ , y2 D 1:7 sin µ, z2 D 0:05,
0± 6 µ 6 180± ). Comparing the stress components in Fig. 9 with those in Fig. 8,
it is seen that the maximum principal stress at the adhesive interface along the rivet
hole is much smaller than that at the left edge of the interface (x2 D ¡l2 , y2 D 0,
z2 D h2 ). From the maximum principal stress criterion it can be concluded that the
failure of the joint, if any, will be initiated from the left edge of the interface but
never from the rivet hole. The strength corresponding to the initial failure is called
the initial strength of the joint. However, the nal rupture strength of a single-lap
riveted-adhesive joint may be greater than its initial strength (see Section 4.6).
4.5. Prediction of joint strength by elasto-plastic FEA

Modern structural adhesives can develop a large plastic deformation until their
rupture and are so large in strength that the adherends may yield under large loadings
[8, 12, 13]. The experiment showed that the failure of single-lap adhesive joints,
and single-lap riveted-adhesive joints with thin adherends (1.6 mm), was due to
large plastic deformation in the adherends (Table 4, Section 4.5.4). Even when the
Figure 10. Stress– strain curves for the materials used in the FEA.
adherends are thicker (6 mm), the plastic deformation takes place near the adherend
surfaces. In this analysis, non-linearities in the materials and the geometry were
taken into consideration. The von Mises yield criterion was used in evaluating the
yielding. In predicting the joint strength, the maximum principal strain criterion
is applied for the adhesive, and the maximum principal stress criterion for the
adherends and the rivets. The materials used for FEA are the same as those used
in the experiment (Table 1). Figure 10 shows the stress – strain relationships for the
adherends, adhesive, and rivets used in this study. Strength predictions of the three
types of single-lap joints under external bending moments by elasto-plastic FEA are
described as follows.
4.5.1. Strength of single-lap riveted-adhesive joints. For single-lap riveted-

adhesive joints, the nal failure may occur due to adherend failure (for example,
due to large plastic deformation of the adherends) or due to simultaneous failure of
the adhesive and the rivets. Therefore, it is necessary to clarify the failure process
of a single-lap riveted-adhesive joint. In the following, three cases corresponding to
the adhesive debonding process of the single-lap riveted-adhesive joint with 6 mm
adherend thickness (Fig. 2a) are analyzed in detail.
Figure 11 shows the positions of the critical points in the three debonded cases.
The critical points are determined on the basis of analyzing the stress and strain
levels in the regions of stress concentration. Case 1 corresponds to a single-lap
riveted-adhesive joint in which the adhesive is not debonded. When the maximum
principal strain in the adhesive at point D, which is 0.375 mm from the edge of
the interface, reaches its ultimate strain of 0.141, the corresponding joint strength
of 56 kN mm is obtained. The maximum value of the maximum principal stress
in the adherends is 331 MPa at point A. Point A is at the lower surface of the
Figure 11. Positions of the critical points in the three debonded cases.
Table 3.
Strengths of single-lap joints riveted-adherend joints in the three debonded cases
Case 1 Case 2 Case 3

a (mm) 0.0 1.175 2.3
±1 (mm) 10 10 NC
±2 (mm) 0.375 0.375 NC
±3 (mm) NC NC 0.35
¾A (MPa) 331.8 379.2 NC
"D 0.14 0.14 NC
¾r (MPa) 1.7 6.7 14.8
¾C (MPa) 13.5 33.4 684
M (kN mm) 56 64 72
NC D not calculated.
upper adherend and is 10 mm from the left edge of the interface. The maximum
axial tensile stress in the left rivet is very small (25 MPa). Because the stress
levels in the adherends and the rivet are lower than their yield stresses, the joint
can withstand greater loads. In order to evaluate the maximum loading ability of
the joints, single-lap riveted-adhesive joints in which the adhesive is debonded were
analyzed. Debonding processes are simulated by deleting adhesive elements which
are near the upper adherend and the left edge of the adhesive. When the adhesive
elements which are near the upper adherend and the left edge of the adhesive are
deleted, a thin gap of h £ a £ B is simulated, where h, a, and B are the height,
length, and width of the gap, respectively, as shown in Fig. 11. Case 2 corresponds
to a model with a gap of 0:25 £ 1:192 £ 12:5 mm. When the maximum value of
the maximum principal strain in the adhesive is 0.141 at point D, the corresponding
joint strength of 64 kN mm is obtained. The maximum principal stress in the upper
Table 4.
Joint strength and failure modes of the three types of single-lap joints (unit: kN mm)
Designation M (exp.) M (EP-FEA) Failure mode

T1:6 -0-b 4.3 4.0 A-LBD
T1:6 -1-b 4.3 4.0 A-LBD
T1:6 -2-b 4.3 4.3 A-LBD
T1:6 -2-n 4.3 4.3 A-LBD
T3 -0-b 18.8 17.8 A-LBD
T3 -1-b 19.2 NC A-LBD
T3 -2-b 19.0 19.0 A-LBD
T3 -2-n 18.4 18.4 A-LBD

T6 -0-b 56.2 54.2 Ad-R
T6 -1-b 54.2 NC Ad-R
T6 -2-b 72.0 70.5 A-LBD; Ad-R
T6 -2-n 36.0 35.2 R-R
The values of M (bending moments) in column 2 correspond to the joint strengths

obtained by the rupture tests; those in column 3 were obtained by elasto-plastic FEA.
A-LBD: adherends-large bending de ection; R-R: rivets-ruptured; Ad-R: adhesive
ruptured. NC D not calculated.
adherends is 434 MPa at point A. The maximum axial tensile stress in the left rivet
is 35 MPa. Case 3 corresponds to a model with a gap of 0:25 £ 2:6 £ 12:5 mm.
Under the external bending moment of 70.5 kN mm, the critical point in the upper
adherend is not at point A; it moves to point C as shown in Fig. 11, since the cross-
sectional area of the upper adherend through point C is minimum. The maximum
principal stress at point C is 687 MPa. As the maximum principal stress approaches
the ultimate limit of the adherend material (687 MPa), the adherends can no longer
withstand an external load. Thus, the joint strength is determined as 70.5 kN mm.
Table 3 lists the strengths of single-lap riveted-adhesive joints with 6 mm adherend
thickness in the three debonded cases, including the critical point positions and
critical point stresses (strains).
Table 4 lists the predicted strengths of single-lap riveted-adhesive joints with
thicknesses of 1.6, 3, and 6 mm.
4.5.2. Strength of single-lap riveted joints. The failure of single-lap riveted joints
may be due to the rupture of adherends or to the fracture of rivets. It is necessary to
analyze the failure modes. It is shown from FEA that the critical stress in the upper
adherend occurs at µ D 90± , z2 D 0, y2 D 1:7 mm on the left rivet hole. However,
this point is not suitable to be chosen as a critical point, because the stress at this
point is extremely high; in other words, the stress at this point is singular. The stress
at µ D 90± , z2 D 0, y2 D 2:05 mm (±3 D 0:35 mm) is used to evaluate the adherend
strength using the maximum principal stress criterion. The average tensile stress
in the left rivet is used to evaluate the rivet strength using the maximum principal
stress. When an external bending moment of 35.2 kN mm is exerted on the joint,
the average tensile stress in the left rivet is 280 MPa, which is equal to the ultimate
stress of the rivets. The maximum principal stress in the upper adherend at µ D 90± ,
z2 D 0, y2 D 2:05 mm is 289 MPa, which is less than the adherend yield stress
of 424.7 MPa. Thus, the strength of single-lap riveted joints with an adherend
thickness of 6 mm is predicted to be 35.2 kN mm. Table 4 shows the predicted
strengths of riveted joints for 1.6, 3, and 6 mm adherend thicknesses.
4.5.3. Strength of single-lap adhesive joints. Because a singular stress exists

at the edge of the adhesive interface, the failure of a single-lap adhesive joint, in
general, is initiated from the edge of the adhesive interface. After debonding of the
adhesive layer, the loading ability of the joint is reduced; in other words, the initial
joint strength is greater than its successive strengths. Thus, the strength of single-lap
adhesive joints is determined by the initial strength.
The strength prediction of a single-lap adhesive joint has been investigated on
the basis of 2-D plane strain analysis by us [13, 14]. Using the same method for
predicting the strength of single-lap adhesive joints as reported in refs [13 and 14],
the predicted strengths of single-lap adhesive joints with 1.6, 3, and 6 mm adherend
thicknesses are 4, 17.8 and 54.2 kN mm, respectively (see Table 4).
4.5.4. Experimental results and comparisons. Table 4 shows the experimental

results and the results obtained from elasto-plastic FEA. By comparing the FEA
results with the experimental results shown in Table 4, it is found that these two sets
of results are quite coincident. The following conclusions can be drawn. (1) The
failure of the three types of single-lap joints with adherend thicknesses of 1.6 and
3 mm is due to large bending elasto-plastic deformation of the adherends, and not
to the rupture initiated from the edge of the adhesive interface. In this case, the joint
strength depends on the stiffness of the adherends. It is not necessary to use rivets
in single-lap adhesive joints with thinner adherends. (2) The rupture of single-lap
adhesive joints with 6 mm adherend thickness is initiated at the edge of the adhesive
interface in the vicinity where tensile deformation is predominant. The initial failure
of single-lap riveted-adhesive joints with two rivets tted near the ends of the lapped
section is due to the maximum principal strain in the adhesive reaching the ultimate
strain of the adhesive. However, its ( nal) failure is due to the large bending
elasto-plastic deformation of the adherends. The ratio of the strengths of single-
lap riveted-adhesive joints to that of single-lap adhesive joints is 1.28. Therefore,
tting rivets in single-lap adhesive joints with thicker adherends can enhance the
joint strength. (3) The strengths of single-lap riveted-adhesive joints with one rivet
tted at the middle point of the lapped section are almost the same as those of the
corresponding single-lap adhesive joints. (4) Single-lap riveted joints with 6 mm
adherend thickness are ruptured due to yielding of the rivets.
5. CONCLUSIONS
Three-dimensional elastic and elasto-plastic FEM analyses of single-lap riveted-

adhesive joints were carried out. In these analyses, the effects of the ratio, Er =E1 ,
of the rivet Young’s modulus to the adherend Young’s modulus, the rivet initial
tightening force, and the positions of rivets on the interface stress distributions
and the joint strengths were examined. The rupture process of single-lap riveted-
adhesive joints under external bending moments was discussed through simulating
three debonded cases. Contact stress analysis and strength evaluation of single-
lap riveted joints and adhesive joints were also conducted, to compare their failure
mechanism and strength. A method for evaluating the tightening force occurring in
the process of tting rivets was proposed. Rupture tests for measuring three kinds
of single-lap joints were conducted. The following results were obtained:
(1) the joint strength increases as the ratio of Young’s modulus of the rivets to that
of the adherend, Er =E1 , increases;
(2) rivets should be tted at the ends of the lapped section of single-lap joints
with thicker adherends in order to enhance the joint strength. Fitting rivets
in adhesive joints with thinner adherends does not enhance the joint strength;
(3) as the thickness of the adherends increases, the equivalent stiffness constant
of the adherends (including the adhesive), ka , increases, while the equivalent
stiffness constant of the rivet, kr , decreases. The rivet tightening force Fr
is reduced because the stiffness constant of the rivet is reduced. The rivet
tightening force is small for a single-lap adhesive joint with thick adherends;
(4) the initial failure is due to large elasto-plastic deformation of the adhesive in
single-lap riveted-adhesive joints with thicker adherends (6 mm). However, its
nal failure is due to large plastic deformation of the adherends. Fitting rivets
in single-lap adhesive joints with thicker adherends can enhance the rupture
strength. It is not necessary to t rivets in single-lap adhesive joints with thinner
adherends (1.6 and 3 mm).
REFERENCES
1. D. Chen and S. Cheng, Trans. ASME, J. Appl. Mech. 50, 109– 115 (1983).
2. D. W. Oplinger, Int. J. Solids Struct. 31, 2565– 2587 (1994).
3. D. A. Bigwood and A. D. Crocombe, Int. J. Adhesion Adhesives 10, 31– 41 (1990).
4. M. Y. Tsai and J. Morton, Int. J. Solids Struct. 31, 2537– 2563 (1994).
5. W. K. Chiu and R. Jones, Int. J. Adhesion Adhesives 12, 219– 225 (1992).
6. L. Tong, AIAA J. 36, 448– 456 (1998).
7. R. D. Adams and R. Davies, J. Adhesion 59, 17– 33 (1996).
8. R. D. Adams, J. Adhesion 30, 219– 242 (1989).
9. E. Sancaktar and K. Narayan, J. Adhesion Sci. Technol. 13, 237– 271 (1999).
10. T. Sawa, Y. Nakano and K. Temma, J. Adhesion 24, 1– 15 (1987).
11. T. Sawa, K. Nakano and H. Toratani, J. Adhesion Sci. Technol. 11, 1039– 1062 (1997).
12. E. Sancaktar and Y. Wei, J. Adhesion 56, 229 (1996).
13. J. Liu and T. Sawa, J. Adhesion Sci. Technol. 13, 729– 749 (1999).
14. J. Liu and T. Sawa, J. Adhesion 69, 263– 291 (1999).
15. T. Sawa, T. Hirose and Y. Nakagomi, Trans. ASME, J. Pressure Vessel Technol. 118, 115– 120
(1996).
16. T. Sawa, H. Kumano and T. Morohoshi, Exp. Mech. 36, 17– 23 (1996).
17. MARC, Volume C (Program Input), MARC Analysis Research Corporation, Palo Alto, CA
94306, USA (1997).
APPENDIX. DETERMINATION OF THE EQUIVALENT STIFFNESS

CONSTANTS, k a AND k r
The equivalent stiffness constants, ka and kr , are used to evaluate the stiffness of
adherends (including the adhesive) and the rivets in riveted-adhesive joints. The
values of ka and kr depend on the materials used to make the joint, the geometry of
the rivet, the adherends thicknesses, and the adhesive thickness. Considering that
the tightening force in a rivet is the initial internal force and the dimensions of the
(a)
(b)
Figure A1. Models for calculating the equivalent stiffness constants kr and ka . (a) Dimensions of
the riveted-adhesive joint. (b) Stresses and deformation at the tightening state by exerting an initial
displacement ±.
rivet are much smaller than those of the adherends, the region in which the stress
and deformation are affected by the tightening force is limited to near the rivet. Far
from the rivet, the effect of the tightening force on the stress and deformation can
be neglected. Therefore, the model shown in Fig. A1a can be used to calculate the
equivalent stiffness constants ka and kr using elastic nite element analysis. Due
to the symmetry of the joint, only half of the joint is analyzed. The diameters of
the rivet, rivet hole, and rivet head are denoted as 2a, 2b, and 2c, respectively. The
thickness of the adherend is expressed by 2h1 , the adhesive thickness by 2h2 , the
thickness of the rivet head by tr , and the wall thickness of the rivets by ±r . The
outer diameters of the adherend and the adhesive are chosen as three times the rivet
head diameter. By exerting a small downward initial displacement ± at the cross-

section a– a, the rivet is tensioned and the adherends (including the adhesive) are
compressed. Thus, tensile stresses, ¾r , occur in the rivet and compressive stresses,
¾a, on the contact surface between the adhesive and the rivet head are created
as shown in Fig. A1b. In Fig. A1b, ±a denotes the average of the compressive
deformations of the upper adherend (including half of the adhesive). Thus, the total
tensile deformation of the rivet is (2± ¡ 2±a ) and the total compressive deformation
of the upper and lower adherends (including the adhesive) is (2±a ). Stress and
deformation distributions can be obtained by FEM.
The values of kr and ka are determined by
kr D Fr =.2± ¡ 2±a /; (A1)
ka D Fa =.2±a /; (A2)
where Fr (initial tightening force) is the resultant of the tensile stresses, ¾r , and
Fa is the resultant of the compressive stress, ¾a , on the contact surface between
the adhesive and the rivet head. By the way, considering the equilibrium of the
rivet under action of the forces Fr and Fa , Fr and Fa are equal in magnitude. It
should be pointed out that the values of kr and ka are not altered for different initial
displacements, ±.

Journal of Adhesion Science and Technology

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Journal of Adhesion Science and Technology

Uploaded by

Copyright:

Available Formats

This article was downloaded by: [University of North Carolina]

On: 12 November 2014, At: 10:16

Journal of Adhesion Science

Stress analysis and strength

To link to this article: http://dx.doi.org/10.1163/156856101743300

PLEASE SCROLL DOWN FOR ARTICLE

Stress analysis and strength evaluation of single-lap

JIEMIN LIU 1 and TOSHIYUKI SAWA 2;¤

Received in  nal form 6 July 2000

2. FINITE ELEMENT ANALYSIS

3. EXPERIMENTS TO MEASURE THE JOINT STRENGTHS

3.1. Preparation of the specimens

Adherend Adhesive Rivet

E: Young’s modulus; º: Poisson’s ratio; ¾y : yield stress; ¾ u : ultimate stress; "u :

oven at 60 ± C for 2 h and at room temperature for 24 h.

3.2. Determination of the rivet tightening force, Fr

Figure 3. Sketch for determining the rivet tightening force, Fr .

by the following equation:

1 D 1a C 1r or 1 D Fr =kr C Fa =ka ; (5)

Fr D [kr =.ka C kr /].Pu ¡ Pry /: (6)

It should be pointed out that the deformation (the amount of compressive

3.3. Measurement of the joint strengths

Figure 4 shows a schematic diagram of the experimental set-up for single-lap

4. ANALYTICAL RESULTS AND COMPARISON WITH THE EXPERIMENTAL

Figure 8. Stress distributions at the interface (¡l2 6 x2 6 ¡lr ¡ b, y2 D 0, z2 D h 2 ). 2l2 D 25 mm;

4.4. Stress distributions at the adhesive interface

4.5. Prediction of joint strength by elasto-plastic FEA

4.5.1. Strength of single-lap riveted-adhesive joints. For single-lap riveted-

Case 1 Case 2 Case 3

Designation M (exp.) M (EP-FEA) Failure mode

T3 -2-n 18.4 18.4 A-LBD

The values of M (bending moments) in column 2 correspond to the joint strengths

4.5.3. Strength of single-lap adhesive joints. Because a singular stress exists

4.5.4. Experimental results and comparisons. Table 4 shows the experimental

Three-dimensional elastic and elasto-plastic FEM analyses of single-lap riveted-

APPENDIX. DETERMINATION OF THE EQUIVALENT STIFFNESS

head diameter. By exerting a small downward initial displacement ± at the cross-

You might also like

Received in nal form 6 July 2000