An investigation into using finite element analysis for epoxy resin joints

Finite element analysis (FEA) is a well-established tool for the study of engineering components, but designs often involve the use of materials that are bonded together using adhesives. The accuracy of using linear elastic FEA to model epoxy/aluminium bonds is investigated by the comparison of actual results with computer-predicted data. From the results obtained it is shown that it is possible to model epoxy resin joints, provided that careful mesh refinement is used in the interface region so that the effect of nodal stress averaging is overcome. The FE models were then used to study failure modes and it was established that both elastic or plastic failure of the joints can occur depending on the magnitude of any interface stress concentrations present.