Modelling of adhesive bonding for multi-material design

Important results from the project

The aim was to develop a simulation tool to increase the possibility to design multi-material components in accordance with the light-weight strategy “right material at the right place” and thereby enable further reduction of component weight, increased efficiency in design and feasibility analysis of new products. The project has fulfilled the goals and resulted in a finite element (FE) based simulation model for prediction of component deformation, quality and risk of failure in adhesive, and hybrid joints during curing, which can be applied on a general geometry.

Expected long term effects

The project has resulted in increased knowledge regarding factors affecting the deformations created by the delta alpha-phenomena during curing of adhesively bonded multi-material combinations. VCC applied the material model to a larger section of an adhesively hybrid bonded multi-material BIW structure. Gestamp used the material model to predict the adhesion quality of an adhesively bonded aluminium chassie component and carbonfibre reinforced plastic. Further work with incorporation of more cases is required before the model can be fully implemented in the industry.

Approach and implementation

The investigations and experiments in the project resulted in a methodolgy for generation of information and data regarding the properties and behaviour of adhesives and materials during the curing process, which can be applied to a general case in the continued development and implementaion. The project plan and execution resulted in a simulation tool efficiently supporting feasibility analysis and enables process simulation of complex shaped parts and large structural assemblies. A design guidline for support has also been delivered.