The design considerations for optimizing a bonded joint should mainly include:
• avoiding peel forces
• generating compressive stress rather than tensile stress
• avoiding stress concentrations in the bond-line [1]
The stress concentrations present at the ends of the overlapped joints are due to the difference in axial strain occurring in the adherents as a result of the stress transfer in the adhesive joint (Figure 6.5).
An equal stress distribution in adhesive joints can be improved by several approaches. Some alternatives for the creation of lap shear joints are illustrated in Figure 6.6; other possibilities to improve the stress distribution in lap shear joints include the use of adhesives with different moduli of elasticity (Figure 6.7) as described by Schliekelmann [2].
Some simple design rules to avoid peel forces at the ends of bonded joints are shown schematically in Figure 6.8
In many cases tensile stresses can be changed into compressive stress by using a different assembly of the parts to be bonded (Figure 6.9).