Materials Today: Proceedings 50 (2022) 1080–1087

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Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

Finite element studies of bolted, riveted, bonded and hybrid step-lap

joints of thick plate
Smit Mistry ⇑, Poojan Joshi, Rahul Dhandhukiya, Shivam Gandhi, Nayan Bhanushali, Chirag Desai
R. N. G. Patel Institute of Technology, Surat, Gujarat, India

a r t i c l e i n f o a b s t r a c t

Article history: The application of the step lap joint has been increased due to its good characteristics such as lightweight,
Received 21 May 2021 high stiffness, and good fatigue durability. Moreover, it has a wide application in the aerospace, automo-
Received in revised form 27 June 2021 tive and marine sector because of its efficient strength and less stress concentration. The present study is
Accepted 26 July 2021
concentrated on the effect of the kind of joint used for lap joint like the adhesive joint, riveted joints, and
Available online 6 August 2021
bolted joints. In addition, the length of the steps has been changed to study the behavior of adhesive lap
joint in detail. Also, the hybrid joint such as a bolted-adhesive and riveted-adhesive joint is examined in
Keywords:
the current study. The variation in the number of bolts and rivets are made for detailed analysis. The main
Step lap joint
Adhesive Joint
objective of this project is to analyze the step lap joint with different length, different material for adher-
Riveted Joint end and adhesive and also compare it with different mechanical fasteners such as rivets and bolts con-
Bolted Joint sidering hybridization of it with and without the adhesive, Finite Element Analysis (FEA) is carried out
Hybrid Joint in ANSYS Workbench for analysis and SolidWorks software is used for 3-D modelling.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Con-
ference on Functional Material, Manufacturing and Performances

1. Introduction
Different types of bonded joints are available, such as single lap
joints, scarf joints, tapered joints and step-lap joints. Single lap
joints, however, allow the surface to be adverse to aerodynamic
efficiency and are suitable for the connection of low thick lami-
nates. The methods of bonded joint repairs are preferable to the
thick laminate, scarf or step-lap. The removal of the damaged area
and the tapering process of the perimeter of the undamaged por-
tion of the composite defines a scarf joint repair. Then a patch is
cut out, scarfed and tied to the opening [1,2].
A step-lap joint is essentially the same as a scarf joint, but the
step-lap joint isn’t a simple taper but has several uniform taper
steps (Fig. 1). Typically, both scarf and step-mount attachment
repairs are costly and time-consuming to perform, so the load
transfer behaviour of this repair system needs to be understood
before implementing the structure. In the composite structure of
thickness greater than 4 mm, a stepped lap connected joint is
widely used because the load transfer is uniformed with shear
through step lap joint [3,4].
The present work focuses on the thorough comparison of
mechanical joints such as bolted and riveted joints with step lap
⇑ Corresponding author.
E-mail address: mistrysmit16@gmail.com (S. Mistry).
and hybrid joints through the Finite Element Method (FEM) in
Ansys Workbench. Moreover, the length of the steps was varied
to check the optimality of the step’s length and to study the behav-
ior of the step lap joint. In addition, the number of bolts and rivets
were varied to study the effect of the number of bolts and rivets on
the step lap joint. Also, rivets and bolts considering hybridization
of it with and without the adhesive were analyzed. Besides, differ-
ent materials for adhesive and adherend were compared.
2. Problem statement
The widely used joint is an adhesive bonded joint for step lap.
The literature shows that the FEA method has been adopted to
evaluate stress parameters and adhesive joint strength. The study
of static and fatigue strength was concentrated mostly. The pro-
gressive failure process, multicontinum theory and the stress
release rate are just some of the methods used to determine stress
conditions and fatigue behavior of the joint. Many different
approaches, such as bi-adhesive joint and hybrid joint, were con-
sidered to improve joints strength. However, less study was con-
ducted on the different length of the step lap and then the
hybridization was explored. The present study bases on an assess-
ment of the step lap joint with different joint lengths and then
check it for the strength of the joint with different types of
mechanical fastenings such as rivets and bolts [5–14].

https://doi.org/10.1016/j.matpr.2021.07.467
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances
S. Mistry, P. Joshi, R. Dhandhukiya et al. Materials Today: Proceedings 50 (2022) 1080–1087

Fig. 1. Step lap Joint (Adhesive joint).

This study aims to analyse the capacity of the load carrier, stress
and the deformation of the Three-step lap joint based on the prob-
lems and the prior analysis of research gaps. This objective is
achieved with the focus of studying the step-lap joint with differ-
ent lengths, different materials for the adhesive and adhesive and
also used for various mechanical connectors. In addition, the com-
parison of step laps is analysed in the light of stress and deforma-
tion parameters by adhesive and mechanical joints, such as bolted,
riveted joint. FEA was adopted to perform the static structural
analysis in ANSYS Workbench. Before that SolidWorks (3D mod-
elling software) was used for modelling. The detailed methodology
is explained in the next section.

3. Methodology
Fig. 2. 3D model of three-step lap joint.
3.1. 3D modeling

First of all, 3D modelling of the three-step lap joint was done. Table 2
The dimensions of the three-step lap joint were taken from the Dimensions of varying steps.
standard research paper [15]. Dimensions are shown in Table 1. No. Length Unit
3d modelling was done in SolidWorks software (Fig. 2).
1 2–21-2 mm
Total 5 such 3d models were created whose overall length, 2 4–17-4 mm
thickness, width and other dimensions were identical. However, 3 6–13-6 mm
the step length was varied, whose dimensions are shown in Table 2. 4 8–9-8 mm
Fig. 3 depicts the model of 2–21-2 length of Table 2. Similarly, 5 10–5-10 mm
other models were created keeping all other dimensions as same.
Fig. 4 shows the 3D model of joint with 3 rivets and 3 bolts. ware for simulation to help engineers detect weak points, voltage
Similarly, joints with 1 rivet and 1 bolt were made. All these areas and other design failures. Typically, the results of an FEA-
mechanical joints were analyzed with and without adhesive. based simulation are shown with a colour scale showing for
Besides, two different materials for the same plate were also ana- instance the pressure distribution over the object. FEA was used
lyzed. In addition, hybrid adhesive i.e., two different adhesives in in ANSYS 19.2 software. The first step was to import and assign
the same plate were also taken for FEA. the material to geometry in ANSYS [18–24].

3.2. Material selection 3.3.1. Meshing

After assigning the materials, the mesh was created. The goal of
Aluminium alloy and Carbon Fiber used in Plates of Three-step Finite Element Analysis (FEA) is to simulate some physical phe-
lap joint. The material used for adhesive is Epoxy resin and Ara- nomena using a numerical technique known as the Finite Element
ldite. Moreover, Stainless steel is used for rivet and nut-bolt. The Method (FEM). Any continuous object has infinite degrees of free-
mechanical properties of all the materials are shown in Table 3 dom (DOF), making hand calculations impossible. As a result, in
[16,17,25–28]. FEM, we create a mesh that divides the domain into a discrete
number of elements from which the solution can be calculated.
3.3. Finite Element analysis (FEA) The data is then interpolated over the entire domain. Fig. 5 shows
the example of meshing done in a Three-step lap joint. The size of
The FEA is the simulation utilizing the digitally called finite ele- the meshing was kept at 3 mm.
ment method of any physical phenomenon (FEM). FEA is a numer-
ical method used to predict how a part or assembly under certain 3.3.2. Boundary conditions
conditions will behave. It provides the foundation for modern soft- After Meshing, applying the boundary conditions is the crucial
step. For tensile stress, one end was fixed of three-step lap joints.
Table 1
Whereas, the force was applied on another end in x-direction as
Dimension of 3 step lap joint.
shown in fig. The given force was 20,000 N. Fig. 6 shows the bound-
Aspect Dimensional Parameters Unit ary conditions for tensile stress. For bending stress, the boundary
Length 453.74 mm condition applied where both ends were fixed. Whereas, the force
Thickness 4.85 mm was given on the top surface of both plates as shown in Fig. 7. The
Width 50 mm
given force was the same as 20000 N.
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S. Mistry, P. Joshi, R. Dhandhukiya et al.
Fig. 3. 2–21-2 model.
Fig. 4. 3D model of joint with 3 rivets and bolts.
4. Results and discussion
As shown in Table 2, a five-step lap adhesive joint was analyzed
for FEM (Finite Element Method). The results of bending stress,
tensile stress, von misses stress, and deformation was obtained.
Figs. 8, 9, and 10 show the total deformation, von misses stress
and tensile stress for tensile loading. Figs. 11, 12, and 13 depict
the total deformation, von misses stress and bending stress for
bending loading. Similarly, all 5 three-step lap joints (Table 2) were
analyzed. Besides the FEA of step lap joint for 3 rivets,3 bolts, one
rivet, one bolt, with and without adhesive, hybrid (multi adhesive)
were analyzed for FEA.
Fig. 14 shows the graph of the result for shear stress in the first
five models in which step length was varied. Also, from the figure,
it was observed that the maximum shear stress produced in the 6–
Fig. 5. Meshing.
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Materials Today: Proceedings 50 (2022) 1080–1087
13-6 model was 29.223 MPa and the minimum stress produced in
the 8–9-8 model was 27.372 MPa.
Tables 4 and 5 demonstrates the results of total deformation,
von misses stress, and normal stress for bending and tensile load-
ing for all the models. In addition, Figs. 15 and 16 shows the graph
of results for tensile and bending loading. Figs. 17 and 18 depict the
force vs displacement diagram of the 2–21-2 model for tensile and
bending loading.
From the graph, it can be stated that for the application of ten-
sile loading, the model 2–21-2 and multi adhesive induces lesser
stress and deformation comparatively. So, both are the safer and
most suitable models to use in the application of tensile loading.
Besides, the model having different plate materials with the adhe-
sive generates the maximum amount of stress. So, it can be stated
that this model is not suitable for tensile loading application. It was
also observed that there was no significant change in the value of
deformation.
For bending load, it can state that the model 2–21-2 and multi
adhesive induces lesser stress and deformation comparatively. So,
both are the safer and most suitable models to use in the applica-
tion of bending loading. Besides, the model has one rivet with or
without the adhesive generates the maximum amount of stress.
So, it can be stated that this model is not suitable for tensile load-
ing application. It was also observed that there was no significant
change in the value of deformation.
Figs. 17 and 18 depict the force vs deformation chart for tensile
and bending stress of 2–21-2 simple adhesive model, 3 bolts with-
out adhesive, and 3 rivets without adhesive. According to that, the
behavior of the graph observed is linear. The graph of 3 bolts and 3
rivets are overlapped on each other as the values of the axis is
similar.
S. Mistry, P. Joshi, R. Dhandhukiya et al. Materials Today: Proceedings 50 (2022) 1080–1087

Fig. 6. Boundary condition for tensile stress (One end fixed and force applied on another end).

Fig. 7. Boundary Condition for bending stress (Both ends fixed and force applied on the top surface).

Table 3
Mechanical Properties of Materials.

Materials Aluminium alloy Carbon fibre Epoxy resin Araldite Stainless steel
Density (kg m^-3) 2770 1800 1186 1200 7750
Young’s Modulus (MPa) 7E + 04 – 2.2E + 03 4.89E + 03 1.93E + 05
Young’s Modulus X direction (MPa) – 2.3E + 05 – – –
Young’s Modulus Y direction (MPa) – 23,000 – – –
Young’s Modulus Z direction (MPa) – 23,000 – – –
Poisson’s ratio 0.33 – 0.259 0.35 0.31
Poisson’s ratio XY – 0.2 – – –
Poisson’s ratio YZ – 0.4 – – –
Poisson’s ratio XZ – 0.2 – – –
Bulk Modulus (MPa) 6.8627E + 04 – 1.5214E + 03 – 1.693E + 05
Shear Modulus (MPa) 2.6316E + 04 – 8.7371E + 02 – 7.3664E + 04
Shear Modulus XY (MPa) – 9000 – – –
Shear Modulus YZ(MPa) – 8214.3 – – –
Shear Modulus XZ(MPa) – 9000 – – –
Tensile Yield Strength (MPa) 2.8E + 02 – – – 2.07E + 02
Compressive Yield Strength (MPa) 2.8E + 02 – – – 2.07E + 02
Tensile Ultimate Strength (MPa) 3.1E + 02 – – – 5.86E + 02

Fig. 8. Total deformation for tensile loading (2–21-2 model).

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Fig. 9. Von misses stress for tensile loading (2–21-2 model).

Fig. 10. Tensile stress for tensile loading (2–21-2 model).

Fig. 11. Total deformation for bending loading (2–21-2 model).

Fig. 12. Von mises stress for bending loading (2–21-2 model).

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Fig. 13. Normal stress for bending loading (2–21-2 model).

29.5

29
shear stress

28.5

28

27.5

27

26.5

26
10*5*10 8*9*8 4*17*4 6*13*6 2*21*2
length of steps

Fig. 14. Graph of result for shear stress.

Table 4 Table 5
Results of Tensile loading. Results of Bending Loading.

Models Deformation Von-misses Normal Models Deformation Von-misses Normal stress

(mm) (MPa) stress (MPa) (mm) (MPa) (MPa)
10*5*10 0.53826 122.93 152.79 10*5*10 141.72 3925.1 4630
8*9*8 0.56867 128.73 172.57 8*9*8 166.42 4121.4 5024
4*17*4 0.53573 126.44 156.82 4*17*4 141.18 3908.6 4755.2
6*13*6 0.53737 122.98 161.01 6*13*6 141.29 3934.3 4645.8
2*21*2 0.53658 122.91 161.01 2*21*2 141.25 3893.6 4654.6
1 rivet without adhesive 0.56248 216.63 177.42 1 rivet without adhesive 166.71 5578.4 4932.6
1 rivet with adhesive 0.56453 220.71 169.97 1 rivet with adhesive 165.27 5068.4 4922.5
3 rivets with adhesive 0.56425 225.8 175.51 3 rivets with adhesive 163.6 4637.6 4886.9
3 rivet without adhesive 0.56126 225.65 174.42 3 rivets without adhesive 164.94 4970.1 4984.3
1 bolt without adhesive 0.56235 178.84 159.54 1 bolt without adhesive 166.3 4778.5 4929.3
1 bolt with adhesive 0.56457 182.04 156.96 1 bolt with adhesive 164.94 4799.5 4919.6
3 bolts with adhesive 0.56328 180.46 157.07 3 bolts with adhesive 162.83 4092.1 4882.4
3 bolts without adhesive 0.56072 163.89 159.2 3 bolts without adhesive 164.06 4104.5 4878.4
Different plate material with 0.62217 219.59 217.56 Different plate material with 84.058 7204.7 5326.2
adhesive adhesive
Different plate material with 1.353 211.35 180.35 Different plate material with 105.29 5443.8 5624.2
1rivet 1rivet
Different plate material with 1.0978 182.21 175.46 Different plate material with 104.73 5778.8 5629.1
1bolt 1bolt
Multi Adhesive 0.53638 122.92 161.01 Multi Adhesive 141.16 3892.7 4653.5

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Fig. 15. Graph of results for tensile loading.

Fig. 16. Graph of results for bending loading.

5. Conclusion
After analyzing the three-step lap joint with adhesive and
mechanical joints by Finite Element Analysis (FEA), the following
conclusions are derived.
 For tensile loading, the 2–21-2 and multi adhesive model are
the kind of joints that induces lesser stress and deformation
compared to other models. Therefore, based on stress and
deformation parameters, the application of those model is pre-
ferred over other models.
 However, there is no significant change in the value of deforma-
tion. Henceforth, the slight variation in the value is also consid-
ered for the concluding parameters.
 For bending load, it can state that the model 2–21-2 and multi
adhesive induces lesser stress and deformation comparatively.
So, both are the safer and most suitable models to use in the
application of bending loading.
 Besides, the model has one rivet with or without the adhesive
generates the maximum amount of stress. So, it can be stated
that this model is not suitable for tensile loading application.
 Moreover, the behavior of force vs deformation graph for tensile
and bending loading is linear.
 Therefore, if the current work is to be concluded in a line, then
the 2–21-2 simple adhesive model is best among all the model
analyzed.

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S. Mistry, P. Joshi, R. Dhandhukiya et al.
Fig. 17. Force vs Deformation graph for Bending loading.
Fig. 18. Force vs Deformation graph for Bending loading.
CRediT authorship contribution statement
Smit Mistry: Conceptualization, Methodology, Data curation,
Writing - original draft, Visualization, Investigation, Validation,
Writing - review & editing, Funding acquisition. Poojan Joshi: Con-
ceptualization, Methodology, Software, Data curation, Writing -
original draft, Visualization, Investigation, Validation, Writing -
review & editing, Funding acquisition. Rahul Dhandhukiya: Fund-
ing acquisition, Visualization, Data curation. Shivam Gandhi:
Funding acquisition, Visualization, Software. Nayan Bhanushali:
Funding acquisition, Visualization. Chirag Desai: Conceptualiza-
tion, Methodology, Supervision, Funding acquisition, Visualization.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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