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Abstract Adhesive bonding of composite materials has become increasingly crucial for advanced engineering applications, offering unique advantages for lightweight and high-performance designs. This study presents a novel framework, physics-informed failure mode proportion prediction (PIFMP) model, for predicting failure mode proportions in composite adhesive joints, addressing critical gaps in understanding mixed-mode failure behaviors. In contrast to conventional approaches that focus solely on force or stress prediction, this research integrates important parameters from multistage manufacturing processes (MMPs) and simulation data into a physics-informed machine learning (PIML) framework, enabling proactive failure prediction and design optimization. The proposed framework unifies data-driven machine learning models with features derived from finite element analysis (FEA), incorporating cohesive zone modeling (CZM) to capture the physical dynamics of adhesive behavior under lap shearing. By embedding FEA-based physics features into the machine learning process and leveraging a time-series transformer model to analyze the temporal progression of interfacial damage and separation, the framework ensures predictive accuracy and physics-informed consistency, enabling precise analysis of failure mechanisms. The empirical study validates the effectiveness and the reliability of the framework, demonstrating enhanced predictive performance through cross-validation. The work establishes a foundational approach for failure analysis and provides a robust basis for future advancements.
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This content will become publicly available on March 1, 2026
Comparative Analysis of Different Adhesive Model Representations in Single Lap Joints Using Finite Element Analysis
This study addresses an existing gap in the literature by providing a comparative analysis of various adhesive model representation approaches, using cohesive zone models—both local and continuum models. Through a systematic investigation of stress distribution and force–displacement characteristics across different modeling techniques, we reveal the advantages and limitations of each method. This study provides a comparison of various adhesive modeling approaches, including single-row cohesive elements, interfacial elements, middle cohesive elements, and single-row continuum solid elements, highlighting their effects on stress distribution and failure modes in single lap joints across a range of adherend thicknesses and overlap lengths. The findings demonstrate that the choice of modeling techniques yields a similar prediction of failure modes in single lap joints under tensile loading. Consequently, choosing among these methods can be guided by the level of detail in capturing localized damage mechanisms. The results offer a foundation for informed decision making in adhesive modeling, with implications for improving joint design and reliability in real-world applications.
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- Award ID(s):
- 2052738
- PAR ID:
- 10575470
- Publisher / Repository:
- Applied Sciences
- Date Published:
- Journal Name:
- Applied Sciences
- Volume:
- 15
- Issue:
- 5
- ISSN:
- 2076-3417
- Page Range / eLocation ID:
- 2661
- Subject(s) / Keyword(s):
- single lap joint cohesive zone modeling finite element analysis adhesive modeling techniques adhesive bonding
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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