Influence of Geometrical Design on the Load Bearing Performance of Structural Steel Components
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Keywords:
Structural Steel, Properties, Optimization, Characterization, Manufacturing MethodsAbstract
The increasing demand for lightweight and resource efficient components in critical sectors
like aerospace and structural engineering has driven the integration of advanced methods such as additive
manufacturing (AM) and topology optimization (TO). Structural steel, while valued for its strength, often
results in components that are significantly over engineered for their specific applications. This study
investigates the lightweighting potential of an S275N structural steel bracket using the finite element
method (FEM). A 3D model with an initial mass of 1.8636 kg was analyzed under a 20 kN static load
with fixed supports to establish baseline performance. The initial FEM analysis revealed a minimal
maximum deformation of 0.02 mm and a maximum von Mises stress of 84 MPa, which is well below the
material's yield strength. Crucially, the analysis showed that stress was highly concentrated around
support features, leaving large regions of the bracket under utilized. Following this analysis, Topology
Optimization (TO) was applied to the design, successfully generating a new, efficient geometry with a
50% mass reduction. The optimized topology strategically maintains a continuous load path and retains
material in high stress concentration zones while eliminating non structural mass. This research serves as
a practical validation of the design for additive manufacturing (DfAM) workflow, demonstrating how
computational analysis can produce structurally strong, lightweight designs perfectly suited for
fabrication using modern AM processes.
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