Design and Optimization of a Laser-Welded Corrugated-Core Steel Structure for Monopoles

Abstract

Designing lighter structures which are resistant to environmental forces, such as wind, is of major importance as there is less usage of material. A lightweight structure is more cost effective and enables innovation in design. In this study, a laser-welded corrugatedcore steel sandwich structure is designed and optimized to reduce the amount of material used for manufacturing monopoles. A model of an existing tower, designed to resist cyclonic wind forces in Mauritius, is obtained from industry and the optimization process is carried out following a parametric study whereby several design variables are introduced. The weight of the structure is taken as the objective function for minimization. The design constraints are set as per the structural standard ANSI/TIA/EIA-222F and the limitations in manufacturing of the structure. To choose the optimum model, the reduced mass and the structural performance of the corrugated structure are compared to those of an existing tower. Once the optimum model is selected, a finite element analysis is carried out whereby the displacements and stresses developed are analyzed. Ultimately, a mass reduction of 26.1 % is achieved and the results show a safe structure.