Self-Weight Minimization of 3D-Printed Corrugated Web Beams Using Finite Element Analysis

Abstract

Additive manufacturing, commonly known as 3-D Printing, is a relatively new manufacturing method. Although it is now widely used in the industrial field, its use in structural field is still very limited. A few works were made to explore the potentiality of using additive manufacturing in structural engineering. This paper is devoted to exploring the benefits of additive manufacturing in the field of structural engineering and more specifically, steel structures. The objective is to explore the possibility of modifying the shape of structural systems to decrease their weights, without effecting their performance and load carrying capacity. This will show how advantageous can the use of additive manufacturing in the field of structural engineering be, since complexity of fabrication is not a problem and does not add any cost, while the overall cost of the beam will be reduced by reducing its weight. Initially unmodified-shape model of a corrugated web beam was analyzed using Finite Element Analysis and then the shape of the cross section was modified following the stress contours. Finite Element Analysis was conducted on the modified-shape model and the results were compared with those of the original model. It was found that the modified model could withstand the same loadings as the original one with 19.26% reduction in weight.