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Astrium Example Joint Design
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Verification steps in the analysis of bonded joints: 1. Recalculate stress distribution of the test sample (see example below); normally same adhesive tested at RT 2. Determine peak stress at the edge of the sample 3. Calculate stress distribution in the new joint 4. Demonstrate positive margin of sMoS=(Smaxsample/(Smaxjoint*Jult))-1 Safety factor Jult=1.5 to 2.0 5. Note: test sample needs to be similar or stiffer than the new joint (Kt,mech less-equal than in new joint) 6. Verification of bonded joints under extreme temperatures (outside qualification temperatures of adhesive) needs te 7. Warning: in case of CFRP the out-of-plane skin strength (similar to 90° strength of UD) can be very and thus failu Liner-elastic Analysis of Standard Joint under Test Loads; EA9321 acc.to ASTM D 1002 E-modulusthicknessCTE G-modulus E*T Ce R lambda Fth Fth0 Adherend 1 70000 1.6 0.00E+00 112000 56000 0.190179 0.436095 0.00E+00 8.004302 Adherend 2 70000 1.6 0.00E+00 112000 Adhesive 0.1 1065 max. Fthermal= 0 Length[mm] 12.7 Line Load [N/mm] 350 Smean= 27.55906 Temperature Kt,mech= 2.791069 1 0 76.91922 0 76.91922 2 0.254 68.92085 0 68.92085 3 0.508 61.76897 0 61.76897 4 0.762 55.37575 0 55.37575 5 1.016 49.66266 0 49.66266 6 1.27 44.55953 0 44.55953 7 1.524 40.00368 0 40.00368 8 1.778 35.93917 0 35.93917 9 2.032 32.31606 0 32.31606 10 2.286 29.08986 0 29.08986 11 2.54 26.22095 0 26.22095 12 2.794 23.67409 0 23.67409 13 3.048 21.418 0 21.418 14 3.302 19.42496 0 19.42496 15 3.556 17.6705 0 17.6705 16 3.81 16.13307 0 16.13307 40 50 60 70 80 90 Mechanical and Thermal Stress in Te Shear Stress [MPa]
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Transcript of Astrium Example Joint Design
Test SampleVerification steps in the analysis of bonded joints:1. Recalculate stress distribution of the test sample (see example below); normally same adhesive tested at RT2. Determine peak stress at the edge of the sample3. Calculate stress distribution in the new joint4. Demonstrate positive margin of safetyMoS=(Smaxsample/(Smaxjoint*Jult))-1Safety factor Jult=1.5 to 2.05. Note: test sample needs to be similar or stiffer than the new joint (Kt,mech less-equal than in new joint)6. Verification of bonded joints under extreme temperatures (outside qualification temperatures of adhesive) needs testing at these temperatures7. Warning: in case of CFRP the out-of-plane skin strength (similar to 90 strength of UD) can be very and thus failure of the bonding occurs in the first layer due to out-of-plane stresses in the order of the max. shear stresses in the bonding !!!!Liner-elastic Analysis of Standard Joint under Test Loads; EA9321 acc.to ASTM D 1002E-modulusthicknessCTEG-modulusE*TCeRlambdaFthFth0Adherend 1700001.60.00E+00112000560000.19017857140.43609468170.00E+008.004301941Adherend 2700001.60.00E+00112000Adhesive0.11065max.Fthermal=0Length[mm]12.7Line Load [N/mm]350Smean=27.5590551181TemperatureKt,mech=2.79106868431076.9192157086076.919215708620.25468.9208461134068.920846113430.50861.7689700018061.768970001840.76255.3757472376055.375747237651.01649.6626555489049.662655548961.2744.5595261094044.559526109471.52440.0036817167040.003681716781.77835.9391669841035.939166984192.03232.3160610906032.3160610906102.28629.0898646471029.0898646471112.5426.2209531509026.2209531509122.79423.6740903124023.6740903124133.04821.4179952795021.4179952795143.30219.4249584425019.4249584425153.55617.6705011018017.6705011018163.8116.1330748173016.1330748173174.06414.793796749014.793796749184.31813.6362177347013.6362177347194.57212.6461202606012.6461202606204.82611.8113438396011.8113438396215.0811.1216356549011.1216356549225.33410.5685246341010.5685246341235.58810.1452174062010.1452174062245.8429.846514864809.8465148648256.0969.668748312209.6687483122266.359.609734399809.6097343998276.6049.668748312209.6687483122286.8589.846514864809.8465148648297.11210.1452174062010.1452174062307.36610.5685246341010.5685246341317.6211.1216356549011.1216356549327.87411.8113438396011.8113438396338.12812.6461202606012.6461202606348.38213.6362177347013.6362177347358.63614.793796749014.793796749368.8916.1330748173016.1330748173379.14417.6705011018017.6705011018389.39819.4249584425019.4249584425399.65221.4179952795021.4179952795409.90623.6740903124023.67409031244110.1626.2209531509026.22095315094210.41429.0898646471029.08986464714310.66832.3160610906032.31606109064410.92235.9391669841035.93916698414511.17640.0036817167040.00368171674611.4344.5595261094044.55952610944711.68449.6626555489049.66265554894811.93855.3757472376055.37574723764912.19261.7689700018061.76897000185012.44668.9208461134068.92084611345112.776.9192157086076.9192157086controlFmech=350.3577890287Fth_1=00theoretical max. due to elongation of adherendsFth_2=00theoretical max.
Test Sample
Length of Bonded Joint [mm]Shear Stress [MPa]Mechanical and Thermal Stress in Test Sample
FatigueProposed approach for verification of Fatigue(based on the only available fatigue data foe EA9323 and EA 9432, see 'Materials', approach I) )(based on ESA PSS-03-210 chapter 8, approach II) )a) based on test data on similar joint geometry and materials:I) S(N)average=So,test average/[log(N+100)-1] ; for 10^4 load cycles -> S=So,test/3 , S(10^7)=So,test/6II) S(N)average=So,test average/(N^0.1) ; for 10^4 load cycles -> S=So,test/4 , S(10^7)=So,test/5b) based on test data for same adhesive but different joint:S(N)peak=So,test peak/[log(N+100)-1] or S(N)peak=So,test peak/(N^0.1)N1/[log(N+100)-1]1/(N^0.1)10.99569722011100.96025256780.79432823471000.76862178680.630957344510000.48986165540.5011872336100000.33285387130.39810717061000000.24997287310.31622776610000000.19999826290.2511886432100000000.1666665460.1995262315
Fatigue
Load CyclesStrength RatioFatigue of Adhesives
MaterialsAdhesiveAdherendsE-modult.G-modaveragebondlinebondlinefatigue 10^4endurance 10^7ReferenceType ofadhesivestrainadhesiveshear strengthlengththicknesspeak stresspeak stresssampleEA9321 at RTalu 1.6mm29000.06154527.612.70.2 assumedHysol data sheetASTM D 1002EA9321 at RTCFRP22.5 to 23.70.1 to 0.4A5 development testsEA9321 at +80CCFRP22.40.4A5 development testsEA9321 at +140CCFRP4.90.4A5 development testsEA9321 at -55Calu21PCA developmentEA9321 at RT35000.0251346.153846153828.8EA9321 at +82C12.1EA9321 at +121C7.7EA9321 at +149C5.1EA9321 at +204C3.3EA9313 at RTalu21000.088892912.50.2GOMOS developmentEA9313 at RTtitanium21000.0888922.112.50.2GOMOS developmentEA9323 at RTalu 6.3mm28700.051103.846153846211.4 to 14.6800.1 and 0.32012Eng.Fract.Mech.1996special fatigueEA9432 at RTsteel 3mm43001653.846153846210, 15, 200.123.515Eng.Fract.Mech.1999special fatigueEA 9628 at -55C042catalogueEA9628 at RT24000.055923.076923076941.3cured at 120CEA 9628 at +82C27.5EA9628 at +121C13EA9649 at -55C25.2catalogueEA9649 at RT26.2cured at 180CEA9649 at +149C18.3EA9649 at +204C12.1FM 73 at -55C42.8catalogueFM 73 at RT21400.05823.076923076937cured at 120CFM 73 at +82C27FM 96 at -55C24.6catalogueFM 96 at RT29.9cured at 175CFM 96 at +82C37.1FM 96 at +121C33.4FM 96 at +149C23.6
New JointLinear-elastic Analysis of New Joint under Design LoadsE-modulusthicknessCTEG-modulusE*TCeRlambdaFthFth0Adherend 17000012.30E-057000041176.47058823530.25864285710.50856942212.20E-0380.8491675189Adherend 210000011.00E-06100000Adhesive0.11065max.Fthermal=-90.5882352941Length[mm]20Line Load [N/mm]100Smean=5Temperature100Kt,mech=5.9834900817XiSmechSthermalScombined1029.917450408446.066882301175.984332709620.424.410847666837.586589681861.997437348630.819.917924070530.667108986150.585033056641.216.252107526225.021103478641.273211004751.613.261172194120.414118456433.67529065056210.82091719416.65484533827.47576253272.48.830009067913.587177428122.41718649682.87.205773831211.083727467118.289501298393.25.88076387179.040537778114.9213016498103.64.79995713597.372763344312.17272048021143.91847229656.01114855519.9296208516124.43.19970502024.89915131358.0988563338134.82.61380794563.99059508256.604403028145.22.13645124773.24775136865.3842026163155.61.74781232422.63977301764.38758534191661.43175264612.1414132633.5731659092176.41.17514759321.73197733422.9071249275186.80.96734144421.39446309082.361804535197.20.79970488951.11485499521.9145598846207.60.66527669280.88154210711.54681879982180.55847462020.68483593011.2433105504228.40.47486363410.51656808970.9914317238238.80.4109717240.36975113480.7807228588249.20.36414572950.2382883790.6024341085259.60.33244116530.11672073060.44916189626100.314541475200.31454147522710.40.3097033607-0.11672073060.192982632810.80.3177259154-0.2382883790.07943753642911.20.3389422821-0.3697511348-0.03080885273011.60.3742334867-0.5165680897-0.14233460331120.4250650235-0.6848359301-0.25977090673212.40.4935477109-0.8815421071-0.38799439623312.80.5825253449-1.1148549952-0.53232965023413.20.6956927901-1.3944630908-0.69877030063513.60.8377494112-1.7319773342-0.89422792336141.0145942183-2.141413263-1.12681904473714.41.2335708273-2.6397730176-1.40620219033814.81.5037724097-3.2477513686-1.74397895883915.21.8364192931-3.9905950825-2.15417578934015.62.2453248942-4.8991513135-2.653826419341162.7474693312-6.0111485551-3.26367922394216.43.3637045364-7.3727633443-4.00905880794316.84.1196201487-9.0405377781-4.92091762944417.25.0466061428-11.0837274671-6.03712132424517.66.1831563222-13.5871774281-7.404021105946187.5764668034-16.654845338-9.07837853464718.49.2843958714-20.4141184564-11.1297225854818.811.3778665888-25.0211034786-13.64323688984919.213.9438119304-30.6671089861-16.72329705575019.617.0887847418-37.5865896818-20.49780494512020.9433824277-46.0668823011-25.1234998734controlFmech=100.3446195241Fth_1=89.77609900030theoretical max. due to elongation of adherendsFth_2=-89.77609900030theoretical max.
New Joint
SmechSthermalScombinedLength of bondingS[MPa]Shear stress in bonding
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