An average failure index method based on accurate FEA was proposed for the tensile strength prediction of composite out-of-plane adhesive-bonded π joints. Based on the simple and independent maximum stress failure criterion, the failure index was introduced to characterize the degree of stress components close to their corresponding material strength. With a brief load transfer analysis, the weak fillers were prominent and further detailed discussion was performed. The maximum value among the average failure indices which were related with different stress components was filtrated to represent the failure strength of the critical surface, which is either the two curved upside surfaces or the bottom plane of the fillers for composite π joints. The tensile strength of three kinds of π joints with different material systems, configurations and lay-ups was predicted by the proposed method and corresponding experiments were conducted. Good agreements between the numerical and experimental results give evidence of the effectiveness of the proposed method. In contrast to the existed time-consuming strength prediction methods, the proposed method provides a capability of quickly assessing the failure of complex out-of-plane joints and is easy and convenient to be widely utilized in engineering.
