Optimal design of cold-formed steel lipped channel beams: Combined bending, shear, and web crippling

The load carrying capacity of cold-formed steel (CFS) beams can be enhanced by employing optimisation techniques. Recent research studies have mainly focused on optimising the bending capacity of the CFS beams for a given amount of material. However, to the best of authors’ knowledge, very limited research has been performed to optimise the CFS beams subject to shear and web crippling actions for a given amount of material. This paper presents the optimisation of CFS lipped channel beams for maximum bending, shear, and web crippling actions combined, leading to a novel conceptual development. The bending, shear and web crippling strengths of the sections were determined based on the provisions in Eurocode 3, while the optimisation process was performed by the means of Particle Swarm Optimisation (PSO) method. Combined theoretical and manufacturing constraints were imposed during the optimisation to ensure the practicality of optimised CFS beams. Non-linear Finite Element (FE) analysis with imperfections was employed to simulate the structural behaviour of optimised CFS lipped channel beams after successful validation against previous experimental results. The results demonstrated that, the optimised CFS sections are more effective (bending, shear, and web crippling actions resulted in 30%, 6%, and 13% of capacity increase, respectively) compared to the conventional CFS sections with same amount of material (weight). The proposed optimisation framework can be used to enhance the structural efficiency of CFS lipped channel beams under combined bending, shear, and web crippling actions

Abrasive water jet drilling of advanced sustainable bio-fibre-reinforced polymer/hybrid composites : a comprehensive analysis of machining-induced damage responses

This paper aims at investigating the effects of variable traverse speeds on machining-induced damage of fibre-reinforced composites, using the abrasive water jet (AWJ) drilling. Three different types of epoxy-based composites laminates fabricated by vacuum bagging technique containing unidirectional (UD) flax, hybrid carbon-flax and carbon fibre-reinforced composite were used. The drilling parameters used were traverse speeds of 20, 40, 60 and 80 mm/min, constant water jet pressure of 300 MPa and a hole diameter of 10 mm. The results obtained depict that the traverse speed had a significant effect with respect to both surface roughness and delamination drilling-induced damage responses. Evidently, an increase in water jet traverse speed caused an increase in both damage responses of the three samples. Significantly, the CFRP composite sample recorded the lowest surface roughness damage response, followed by C-FFRP, while FFRP exhibited the highest. However, samples of FFRP and hybrid C-FFRP recorded lowest and highest delamination damage responses, respectively. The discrepancy in both damage responses, as further validated with micrographs of colour video microscopy (CVM), scanning electron microscopy (SEM) and X-ray micro-computed tomography (X-ray μCT), is attributed to the different mechanical properties of the reinforced fibres, fibre orientation/ply stacking and hybridisation of the samples.Peer reviewe

Manufacturing at double the speed

The speed of manufacturing processes today depends on a trade-off between the physical processes of production, the wider system that allows these processes to operate and the co-ordination of a supply chain in the pursuit of meeting customer needs. Could the speed of this activity be doubled? This paper explores this hypothetical question, starting with examination of a diverse set of case studies spanning the activities of manufacturing. This reveals that the constraints on increasing manufacturing speed have some common themes, and several of these are examined in more detail, to identify absolute limits to performance. The physical processes of production are constrained by factors such as machine stiffness, actuator acceleration, heat transfer and the delivery of fluids, and for each of these, a simplified model is used to analyse the gap between current and limiting performance. The wider systems of production require the co-ordination of resources and push at the limits of human biophysical and cognitive limits. Evidence about these is explored and related to current practice. Out of this discussion, five promising innovations are explored to show examples of how manufacturing speed is increasing ? with line arrays of point actuators, parallel tools, tailored application of precision, hybridisation and task taxonomies. The paper addresses a broad question which could be pursued by a wider community and in greater depth, but even this first examination suggests the possibility of unanticipated innovations in current manufacturing practices

Machining Unidirectional Composites using Single-Point Tools: Analysis of Cutting Forces, Chip Formation and Surface Integrity

The need for high quality machining of composite materials is rising due to the increased utilisation of these materials across several applications. This paper presents experimental findings of orthogonal cutting of unidirectional glass fibre reinforced plastic (UD-GFRP) composites using HSS single-point cutting tools. Key process indicators including cutting forces, chip formation and surface integrity were evaluated. Full factorial design is employed with fibre orientation, depth of cut, cutting speed and rake angle as process control variables. Fibre orientation and depth of cut were found to be the most significant factors affecting the investigated responses. Lower cutting forces and better surface quality were obtained at 0o fibre orientation and lower depth of cut. Cutting at 45o fibre orientation generated extremely damaged surfaces with relatively high average surface roughness values and should be avoided in practical applications