Computational Study of Mechanical Strength of ABSSSJ with Hybrid Sisal- Glass Reinforced HDPE Composite Using CZM-based FEM for Automobile Side Body Panel Application

Adhesively bonded joints play (ABJ) a critical role in modern structural applications, particularly in automotive industries where lightweight and high-strength materials are prioritized. The primary objective of this study is to perform a computational analysis of the mechanical strength and debonding behavior of Adhesively Bonded Single-Side Strap Joints (ABSSSJ) composed of hybrid sisal-glass reinforced high-density polyethylene (HDPE) composite as the lower adherend and steel as the upper adherend, designed for automobile side body panel applications. A cohesive zone model (CZM)-based finite element method (FEM) is utilized to simulate the mechanical behavior and evaluate the joint's performance under various loading conditions. Key parameters, including adhesive thickness, overlap length, overlap width, adhesive modulus, and cohesive fracture toughness, are systematically analyzed to determine their influence on the joint's shear and peel stress distribution, failure mechanisms, and load-carrying capacity. The study validates FEM results against analytical solutions and experimental data, revealing the critical role of adhesive properties and joint geometry in optimizing mechanical performance. Sensitivity analyses demonstrate that adhesive thickness and overlap dimensions significantly impact stress distribution and failure modes, while the hybrid composite's stacking sequence affects the joint's overall durability and strength. This computational approach provides detailed insights into the stress distribution and debonding behavior, offering a framework for the design and optimization of high-performance joints in lightweight automotive structures. The findings contribute to advancing the use of sustainable materials, such as hybrid sisal-glass composites, in automotive engineering while ensuring robust structural performance.