Development of optimal internal structural reinforcement for stainless steel hollow sections to maximize mechanical properties and practical performance

Abstract

This research conducts a topology optimization study with added constraints associated with manufacturability and practical implementation. The goal of this study is to maximize the efficiency of material placement within a cross section to limit the overall amount of material needed to sustain a load, resulting in material savings, which would be realized as both cost-saving and sustainability improvements. A variety of profiles are evaluated in 4-point bending and compression simulations with parameters validated through laboratory tested profiles. Profiles are evaluated relative to a standard hollow section profile, where performance is normalized by cross sectional area changes. Data analysis is conducted to combine different evaluation metrics from the bending and compression tests to provide an analysis of the profiles’ performances, both on a high-level basis and for subsets of profiles.

This study finds a range of results for different profile designs, with the top performing profile reaching up to 120% average performance, relative to the benchmarked profile. This increase in efficiency would result in over a 16% decrease in material needed for a given application, providing cost-effectiveness and sustainability. Further testing and analysis is needed to implement the results, but it is hypothesized that more benefits to hollow sections with internal support geometry will be found. One of the strongest hypothesized benefits is in fire resistance capabilities for these sections, as the internal geometry is insulated from the exterior conditions. Overall, the findings of this research study are promising for the development and implementation of internal reinforcements in hollow section members.