A visible deformation on the exterior surface of adhesive-joined automotive body panels along the adhesive application line is called bond-line read-out (BLRO). A 2D finite element model with isotropic linear elasticity and plain strain approximation for a plate/hat design was developed to investigate the physical phenomenon responsible for the formation of BLRO. It was found that a combination of process induced compressive stress on the outer side and tensile stress on the inner side of the exterior panel deforms it into a convex outward shape. The results of this work enables researchers to develop new strategies for reducing BLRO in adhesively bonded exterior panels.
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