Strength Optimisation of Hybrid Bolted/Bonded Composite Joints Based on Finite Element Analysis

A finite element analysis (FEA) was conducted to examine the behaviour of single-lap quasi-isotropic (QI) and cross-ply (CP) hybrid bolted/bonded (HBB) configurations subjected to tensile shear loading. Several critical design factors influencing the composite joint strength, failure conditions, and load-sharing mechanisms that would optimise the joining performance were assessed. The study of the stress concentration around the holes and along the adhesive layer highlights the fact that the HBB joints benefit from significantly lower stresses compared to only bolted joints, especially for CP configurations. The simulation results confirmed the redundancy of the middle bolt in a three-bolt HBB joint. The stiffness and plastic behaviour of the adhesive were found to be important factors that define the transition of the behaviour of the joint from a bolted type, where load sharing is predominant, to a bonded joint. The load-sharing potential, known as an indicator of the joint’s performance, is improved by reducing the overlap length, using a low-stiffness, high-plasticity adhesive, and using thicker laminates in the QI layup configuration. Enhancing both the ratio of the edge distance to the hole diameter and washer size proves advantageous in reducing stresses within the adhesive layer, thereby improving the joint strength.