Simulation-Based Evaluation of Joining Methods of Engineering Plastic Materials

The reliability of joints in plastic assemblies depends strongly on the interaction between material behavior, joining technique, and loading conditions. In this study, Engineering components made from PMMA and PC-ABS were joined using two different methods: laser welding and adhesive joining. The objective is not a full comparative evaluation, but rather to understand the joint formation mechanisms and assess their mechanical response under typical service-level loading. This study primarily focuses on numerical simulation. However, experimental validation and fatigue behaviour analysis are recognised as scope for future research. Numerical simulations were carried out in LS-DYNA R12, where thermal and mechanical coupling were used to model the laser-welded interface, while a cohesive-zone approach represented the adhesive bond line. These models were used to predict pull strength and shear strength, capturing stress distribution, damage initiation, and failure progression for each joint type.