Abstract: A three-dimensional finite element model of the adhesively bonding composite repair structure for cracked aluminum alloy plate was established, and the stress intensity factors around the crack tips were calculated based on the displacement extrapolation method. The run of different uniaxial tension test simulations based on experimental design methods allows us to analyze the effect of different repair parameters on stress intensity factor(SIF), such as the patch length, path thickness and adhesive elastic modulus. The most effective parameter and an optimization of repair operation were achieved by analyzing the SIF using quadratic equation. The finite element results were subjected to the uniaxial tension test. The results show that the patch length is the most effective parameter when the above three factors act at the same times, the failure strength of the repaired plate is increased by 12.1% compared with that of the unrepaired plate, restoring to 90.5% of that of unrepaired plate without cracks.