Joint design · Worked example
Revision record for a bonded-insert overlap
An overlap increase changes the drawing, bond process, root mass and cycle-test conditions, so the revision has to travel through each record.
The revision
The starting overlap is 16 mm with a nominal 0.25 mm bond line. The worked revision extends the overlap to 22 mm so the end of the bond line can be reassessed.
Root mass, usable laminate length and assembly tolerance move with it. The drawing, analysis model and specimen list therefore need the same revision identifier.
A test can stop for two different reasons
The example calls for 5,000 combined cycles and limits relative insert slip to 0.15 mm. Excess slip or a continuous edge crack is a joint stop condition.
A loose fixture is different: the run is invalid because the load cannot be reproduced. It is not recorded as a connection failure.
Specimen and process variables
Surface-treatment batch, measured bond-line thickness, cure time and assembly gap are recorded for each specimen. If one falls outside the process window, the cycle result cannot be attributed to overlap alone.
A different material batch between the starting and revised specimens remains a confounding variable in the hand-off rather than disappearing inside the specimen identifier.
What remains open
The hand-off includes the revised dimension, bond-process window, stop criteria and the link between each specimen and its drawing and layup record.
No pass result is claimed here. Without process measurements and a completed cycle record, the longer overlap remains a change awaiting verification.