Modern Design Methods on Optimised Novel Aluminium Profiles

Within the framework of optimisation of structural elements, in the last years, significant activity has been demonstrated towards developing new sectional designs beyond standardised forms aiming to combine aesthetic innovation, material efficiency, and weight over stiffness, together with structural reliability and manufacture cost savings. Moreover, in terms of sustainability performance, as material-weight reduction leads to less carbon emissions from production to installation processes, the pursuit of suitable materials that can correspond to this challenge becomes imperative. In this context, aluminium is lightweight and corrosion resistant, but due to its low elastic modulus, an increased cross-sectional stiffness is required. In this paper, 16 previously optimised aluminium cross-section profiles are presented and analysed using the finite element analysis software ABAQUS. The obtained ultimate compression resistances were compared with the predictions made in accordance with Eurocode 9, the direct strength method (DSM), and the continuous strength method (CSM). The percentage of difference of these design methods with respect to FE results is depicted. The outcomes point out the vagueness in accuracy of the prediction methods, particularly in reference to stocky or slender cross-sections.