The problematic nature of steel hollow section joint fabrication, and a remedy using laser cutting technology: A review of research, applications, opportunities

Kanyilmaz, Alper

doi:10.1016/j.engstruct.2018.12.080

Cited by 45 publications

(38 citation statements)

References 45 publications

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“…However, the fabrication of the tubular joints is problematic and expensive, because it contains a vast quantity of cutting, drilling, and welding works. The joint fabrication has a major impact on the overall project budget (Kanyilmaz 2019).…”

Section: Introductionmentioning

confidence: 99%

“…Indeed, a significant research effort has been invested worldwide to improve the efficiency of tubular steel joints. A review article by the author (Kanyilmaz 2019) summarizes most of these studies; some of them are listed in Table 1. This article presents a new approach to design complex tubular joints, which is nature-inspired. Tubular structures of nature such as bones, trunks, branches have excellent mechanical properties thanks to their minimized weight and maximized moments of inertia (achieved by removing material from the cross-section centre) (Taylor 2015).…”

Section: Introductionmentioning

confidence: 99%

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Nature-inspired optimization of tubular joints for metal 3D printing

Kanyilmaz

Berto

Paoletti

et al. 2020

Struct Multidisc Optim

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Steel tubular frames are often used to build a variety of structures because of their optimal mechanical properties and attractive forms. However, their joint fabrication involves a vast quantity of cutting and welding works, which induces high labour costs, material waste, and environmental pollution. The construction industry dominates the global carbon footprint, and it needs more sustainable products. Nature’s structures are also often tubular, and their joints (e.g. the knees of a human body, the nodes of trees and plants) are intrinsically optimized to maximize stiffness, resistance, and robustness. The 3D metal printing technology can enable a nature-inspired optimization of steel tubular joints, saving material waste and decreasing fabrication costs as well as the carbon footprint of the sector, since it is free from the constraints of traditional manufacturing. In this study, we designed new tubular joint shapes using solid isotropic material with the penalization (SIMP) method. The objective of the optimization was to maximize the structural performance of the node. The optimized node that used to be achieved after a complex manufacturing process composed of numerous cutting and welding operations, can now be 3D printed and then connected to the rest of the joint leading to a shorter fabrication time. We quantified the joints’ structural performance with different grades of optimization using non-linear finite element analysis. Compared with the conventional joint shapes, the new geometries offered a higher stiffness, resistance, and robustness. We performed a powder bed fusion simulation to analyze the residual stresses after production, and estimated the cost of the new solutions.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Nature-inspired optimization of tubular joints for metal 3D printing

Kanyilmaz

Berto

Paoletti

et al. 2020

Struct Multidisc Optim

Self Cite

View full text Add to dashboard Cite

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“…Nevertheless, a formulation to predict the flexural strength of such a kind of joint has been derived based on the ring model theory developed by Togo [ 66 ] and subsequently deepened by Wardenier, de Winkel, Packer and Zhao [ 67 , 68 , 69 , 70 , 71 , 72 ]. Referring to the second and the third solution, instead, complex structural details have to be conceived, but with the benefit of increasing both stiffness and resistance [ 73 , 74 ]. Instead, the last solution is out of interest because of the required pouring concrete on-site, which slows the construction process [ 54 , 75 ].…”

Section: Introductionmentioning

confidence: 99%

“…Such a solution has only been recently introduced thanks to the adoption of 3D-laser cutting technology (3D-LCT) in the field of civil engineering. However, many efforts have been devoted to this topic, as it is clearly referring to the works by Voth [ 65 , 75 ] and Kanyilmaz [ 73 , 74 ].…”

Section: Introductionmentioning

confidence: 99%

Stiffness Prediction of Connections between CHS Tubes and Externally Welded I-Beams: FE Analyses and Analytical Study

2020

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Double-tee profiles are the most popular members in Europe and the USA for steel structures. However, more efficient cross-sections, such as circular hollow sections (CHSs), could be adopted, since they can provide higher aesthetic, economic and mechanical benefits, with the only drawback of more complex connections such as in the case of I-beams welded to the external surface of circular hollow profiles. Based on the ring model theory, developed by Togo, a rule to design the flexural resistance of such a connection has been included in the Eurocode 3 part 1.8, while no formulations are provided to predict the corresponding initial stiffness. The present work aims at filling this knowledge gap, adopting an approach based on experimental, numerical and analytical work. A monotonic and a cyclic test have been performed on two beam-to-column sub-assemblies; the experimental outcomes have been exploited to validate a finite element (FE) model developed in Abaqus and used to numerically perform the monotonic loading simulations of 30 joints. Afterwards, starting from the extracted information about stiffness, a regression analysis was carried out to define the coefficient of a design equation analytically derived applying the component method approach. The regression analysis is characterized by a coefficient of variation equal to 0.19.

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“…connections between an open and a hollow section. More details about the available literature was previously documented as a first study [22].…”

Section: Introductionmentioning

confidence: 99%

Design and analysis of laser-cut based moment resisting passing-through I-beam-to-CHS column joints

Das

Castiglioni

Couchaux

et al. 2020

Journal of Constructional Steel Research

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Conventional circular hollow section (CHS) connections are often prone to severe local distortion of the CHS column surface, premature flange fractures and demand excessive welding quantity due to much-needed local stiffeners, gusset plates or the direct welding technique. This results in an unavoidable complexity, which leads to a possible economic disadvantage. This paper proposes an innovative I-beam-to-CHS-column "passing-through" connection, which avoids the foretold drawbacks and increases the structural performance of these joints. The moment-resisting connection studied in this article was developed during the research project LASTEICON. It consists of primary beams connected to an I-beam passing through the CHS column through slots obtained via Laser Cutting Technology. The characterization of the ultimate resistance of the proposed connection under symmetrical and antisymmetrical loading conditions in bending is studied in detail. This is performed through a parametric study based on finite element (FE) models, which are primarily validated through an experimental campaign. Encouraging agreements obtained between the numerical and experimental results in terms of joint stiffness as well as joint resistance are presented. Moreover, different failure modes are identified and further characterized by

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The problematic nature of steel hollow section joint fabrication, and a remedy using laser cutting technology: A review of research, applications, opportunities

Cited by 45 publications

References 45 publications

Nature-inspired optimization of tubular joints for metal 3D printing

Nature-inspired optimization of tubular joints for metal 3D printing

Stiffness Prediction of Connections between CHS Tubes and Externally Welded I-Beams: FE Analyses and Analytical Study

Design and analysis of laser-cut based moment resisting passing-through I-beam-to-CHS column joints

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