Optimization of tubular double lap‐joint configuration

Abstract The potential of using composite materials with a polymer base in the automotive industry has grown rapidly. However, one of the main problems encountered is bonding the composite part to metal conventional parts. This paper studies a proposed tubular double lap joint to bond a composite shaft to a metallic end. The automotive driveshaft will be taken as an application throughout this paper. A mathematical model of this joint is presented and a finite element solution has been carried out in order to validate the mathematical model. The optimization objective is to minimize the shear stress level in the adhesive layer. The results show that one can obtain up to 50% reduction in the level of adhesive shear stress. This can be achieved through an optimum selection of lap geometry.