Step lap joints are kinds of lap structures, where butted laminations of each layer are consecutively offset in succeeding layers in the same direction. They are mainly designed this way to reduce the peel stresses at the edges of the overlap area observed in single lap joints. In their service, lap joints are often subjected to bending loads. However, the performance of a step lap joint under flexural loading has not been studied in the literature yet. For this purpose, 3D advanced finite-element (FE) models of the step lap joints were developed via ABAQUS-Standard. DP 460 and A2024-T3 aluminum alloy were used for the adhesive layer and adherends, respectively. The polymeric adhesive layer was modelled using cohesive zone elements with quadratic nominal stress criteria and power law interaction of the energies to characterize the damage initiation and damage evolution, respectively. A surface-to-surface contact method with a penalty algorithm and a hard contact model was used to characterize the contact between the adherends and the punch. Experimental data were used to validate the numerical model. The effects of the configuration of the step lap joint on its performance in terms of the maximum bending load and the amount of energy absorbed were analyzed in detail. A step lap joint with three steps (three-stepped lap joint) was found to show the best flexural performance, and when the overlap length at the upper and lower steps was increased, the amount of energy absorbed by the joint increased markedly.
Keywords: cohesive zone model; energy absorption; four-point bending; step lap joints; step number.