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A micromechanical finite element model for predicting the fatigue life of heterogenous adhesives

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Abstract

Adhesive bonding enables joining together thin and dissimilar materials with a negligible increase in weight, which are attractive features in the automotive and aerospace industries. One of the potential sources of failure in adhesive joints is the fatigue damage in the adhesive layer, which often has a complex heterogeneous microstructure. Characterizing the fatigue life of structural adhesives would be a challenging task via numerical techniques. Besides difficulties associated with modeling the adhesive complex heterostructure, the lack of proper micromechanical models to simulate the fatigue damage in this materials system constitutes the major challenge. In this work, we introduce two new high-cycle fatigue damage models, one for the matrix and the other for the particle-matrix interfaces, to predict the fatigue life of a structural adhesive used for automotive applications. High-fidelity finite element (FE) models of representative volume elements (RVEs) of this adhesive are generated using an automated computational framework, enabling the virtual reconstruction of the microstructure and mesh generation. These 3D FE models are used to calibrate the fatigue damage model parameters with fatigue test data under different loading conditions. The calibrated models are then employed to study the impact of micro-voids and particle-matrix interfacial bonding strength on the fatigue life of the adhesive.

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Acknowledgements

This work was funded by Honda Development & Manufacturing of America, LLC and also in part by an allocation of computing time from the Ohio Supercomputer Center (OSC) and the Ohio State University Simulation Innovation and Modeling Center (SIMCenter). The corresponding author also acknowledges the partial support through Air Force Office of Scientific Research (AFOSR) under Grant Number FA9550-17-1-0350 for the development of microstructure reconstruction and mesh generation algorithms used in this work.

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, The Ohio State University, 201 West 19th Avenue, Columbus, OH, USA

    Mingshi Ji

  2. Honda Development & Manufacturing of America, LLC, 21001 OH-739, Raymond, OH, USA

    Anthony Smith

  3. Department of Mechanical and Aerospace Engineering, Department of Materials Science and Engineering, The Ohio State University, 201 W. 19th Avenue, Columbus, OH, USA

    Soheil Soghrati

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  1. Mingshi Ji
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Correspondence to Soheil Soghrati.

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Ji, M., Smith, A. & Soghrati, S. A micromechanical finite element model for predicting the fatigue life of heterogenous adhesives. Comput Mech 69, 997–1020 (2022). https://doi.org/10.1007/s00466-021-02126-x

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