Optimisation of the protrusion geometry in Comeld™ joints

Design solutions using composite laminates frequently require joining the laminates to metal. A novel approach to such bonding using a sculpted metal surface has been proposed which can be described as a combination of mechanical and adhesive bonding. Optimisation of the protrusion geometry on the sculpted metal surface has been studied numerically with the finite element method using a simplified model for the end protrusion where initial failure is observed. The angle and height of the protrusion are found to significantly affect the stress concentrations around the protrusion which initiate failure. It is predicted that the optimum angle is opposing the shear and that higher protrusions are more likely to prevent joint failure.