Effects of goove geometry on the single lap joints

Adhesively bonded single-lap joints are widely used in aerospace and automotive applications due to their lightweight structure and efficient load transfer. However, conventional flat lap-joint configurations often suffer from severe stress concentrations, particularly peel stresses at overlap edges, which reduce joint strength and fatigue life. This study proposes a novel groove-end joint design incorporating shallow machined channels at the adherend edges. These grooves promote localized adhesive fillets and smoother stress transitions. Finite element analyses—including modal, harmonic, and static simulations—were performed to compare the groove-end joint (Part B) with a conventional flat joint (Part A). Results indicate that the groove-end design increases natural frequencies by approximately 21%, reduces peak stresses by 15%, and lowers total deformation by 32%. It also improves dynamic performance by shifting resonant frequencies to higher ranges, while remaining compatible with standard machining techniques. In conclusion, the proposed design enhances structural performance and offers a practical, cost-effective solution for applications requiring durability and manufacturability.