ISSN 1846-6168 (Print), ISSN 1848-5588 (Online) Preliminary communication

https://doi.org/10.31803/tg-20191106234034

Dimensional Structural Mass Optimization of a Welded I-Profile Bridge Crane Girder

Nedim Pervan, Adis J. Muminovic, Elmedin Mesic, Mirsad Colic, Vahidin Hadziabdic

Abstract: This paper presents the methodology for the development of an optimization model for the optimization of the cross-section dimensions of a bridge crane girder designed
as a welded I-profile. To carry out this optimization, the CAD/CAE software package CATIA V5 was used. In order to develop an optimization model, a CAD geometrical model
and structural analysis model were developed. Optimization was carried out by the iterative method using a simulated hardening algorithm. Additionally, the optimization process
is carried out by using the PEO (Product Engineering Optimization) CATIA module that contains tools for setting the optimization criteria, design parameters, constraints, and
algorithms. The goal of the optimization is to achieve the minimal mass of the girder, while satisfying all functional and geometrical constraints. As a result of the optimization
process, minimal girder dimensions were obtained and due to that, a minimal amount of material can be used for the manufacturing of the girder.

Keywords: crane girder; optimization; parameters; simulated hardening

1 INTRODUCTION via computer software can optimize parts for multiple

constraints simultaneously. Additionally, by using computer
Today, engineers, designers and researchers always try software, it is possible to carry out optimization for the
to optimize theirs designs so that a minimum amount of assembly, not only for one part. The results of optimization
material can be used, or that minimum stresses can be for one part can be used as input data for another part in the
achieved. The allowed stresses are pushed to their minimum assembly. [1–2].
limits. If someone wants to optimize his or her part, from the The subject of the research in this paper is the
aspect of the minimum mass or minimum stresses, they need optimization of the cross-section dimensions of a bridge
to know the precise stress distribution inside the loaded part. crane girder designed as a welded I-profile. Bridge cranes
Computer aided optimization (CAO) is connected to and have two main girders with the rails for wheels movement.
based on the numerical analysis processes. The ends of the main girders are fixed to transverse supports,
The goal of this paper and this research is to present the which have wheels for the movement of the entire bridge
methodology for the development of an optimization model crane (Fig. 1).
for the optimization of the cross-section dimensions of a
bridge crane girder designed as a welded I-profile. A detail
description of the possibilities and characteristics of a PEO
(Product Engineering Optimization) module for the
structural optimization in a CAD/CAE (Computer Aided
Design/Computer Aided Engineering) software CATIA
(Computer Aided Three-dimensional Interactive
Application) is presented. Firstly, it is necessary to develop a
CAD (Computer Aided Design) parametric model and
numerical model of a bridge crane girder. Characteristic
design dimensions of an I-profile are chosen as optimization
parameters.
Dimensioning is the process of choosing the right
dimensions of a machine part in correlation to the function of
that part, its mechanical properties, stiffness, standards, price, Figure 1 Bridge crane with two main girders
etc. That correlation is not always exactly (mathematically)
known. Because of that, the mathematical function (the goal There are a lot of research papers about the structural
function of optimization) is not always easy to set. In this optimization used in the design process. Usually, it is the
case, the only way to carry out optimization is to use the topology optimization, or the optimization of the shape and
iterative process. When using the iterative process, it is size [3-12].
possible to come close to an optimal design by taking into
consideration all of the above-mentioned constraints. It is 2 STRUCTURAL OPTIMIZATION
only possible to carry out this type of iterative process by
using computer software. Sometimes, in terms of classical Optimization is the process of obtaining the best solution
optimization problems, the iterative process is carried out for the given constraints. The main goal of engineers and
only for the most important constraints, other constraints are designers during the design process is to minimize the usage
chosen as constant values. Speed is not the only benefit of of the used materials or to maximize the benefits. The above-
using computer software for the optimization. Optimization mentioned statement must be formulated as a mathematical

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function of some unknown variables. Optimization can be material of the girder. The maximum displacement should
defined as a mathematical problem of the minimization or not be bigger than L/1000. Additionally, it is necessary to
maximization of the function. check the possibility for lateral torsional buckling [15, 16].
There are many different methods for optimization. The The second step is to collect the data about the
most common method for engineers is the method of optimization problem. A static schematic diagram is shown
simulated hardening. This method is based on the process of in Fig. 2a. The length of the girders is 16 m and the maximal
metal cooling during hardening. It was developed by load of the bridge crane is 20 T.
Kirkpatrick, Gellat and Vecchi [13]. For the numerical finite element analysis and for the
Simulated hardening is the stochastic method for optimization analysis of the girders, the CAD/CAE system
searching for a good approximation of the global minimum CATIA is used. The material of the bridge crane is stainless
of the function. The simulated hardening method is based on steel S235.
the process of the heating and controlled cooling of metal In the third step, it is necessary to define the parameters
materials with the goal of exerting influence on the metal that describe the system. The mass of the girder is in the
structure and inside errors. This algorithm can find the global function of the volume (dimensions) of the girder and
minimum in a certain amount of time [14]. material density. The dimensions of the girder cross section
The algorithm begins with the initial design vector X1 are shown in Fig. 2b, and these dimensions are taken as
(iteration number i = 1) and a high value of the temperature design parameters.
T. By random generation of a new point Xi+1, the nearby first The length of the girder L and the material (density of the
point, the value of the goal function can be calculated by material ρ) are constant during the optimization process. Due
using the following equation: to that, they are removed from the optimization problem
formulation. The same applies to the rails. Rails have
ΔE = Ei +1 − Ei = Δf = fi +1 − fi = f (X i +1 ) − f (X i ) (1) standard dimensions (a = 50 mm and c = 40 mm). The rest of
the girder cross section dimensions (b, t1, h and t) are free
If fi+1 is smaller than fi (negative value of Δf), point Xi+1 parameters and they are taken as the design parameters for
is accepted as a new design vector. If Δf has a positive value, optimization.
point Xi+1 is accepted as a new design vector with the
probability of e−ΔE/kT. That means that if the value of a
randomly generated number is bigger than e−ΔE/kT, point Xi+1
is not accepted as a design vector. With this process, one
iteration of the optimization process is finished.
If the point Xi+1 is not accepted, the generation process of
the new point is based on the Metropolis criteria:

 ∆E 
P (Ei +1 ) = exp   (2)
 kT 

For the simulation of the thermal balance achievement

on every temperature, a number of new points is selected (n)
Xi+1. These points must be analyzed for the defined values of Figure 2 a) Schematic diagram of the bridge crane; b) Girder cross section
temperature.
When a number of new design points Xi+1, analyzed for The fourth step is to define the goal function. The goal
the defined value of temperature, become bigger than the of the optimization is to find the dimensions of the girder
number n, the temperature T is reduced by an already defined cross section, which will give the minimum mass of the
factor c (0 < c < 1) and the whole process repeats. It is girder for the applied constraints. The mass of the girder can
considered that the process converges when the value of be expressed as the function of the design parameters.
temperature is small enough or when the change of the value
of the goal function Δf is small enough. f (b, t1 , h, t ) = m = A ⋅ L ⋅ ρ ⋅ g (3)
For good optimization, the most important thing is to
formulate the optimization problem correctly. An optimal In the last step of the optimization, it is necessary to
solution will have satisfactory results only if the optimization define the constraints. Constraints are applied in the form of
problem is formulated in the right way. the allowed values for the maximum stress, deflection and
For the design optimization, a five-step procedure for the lateral torsional buckling.
optimization problem formulation is usually used. The first Moreover, constraints must be applied in the form of the
step is to define the optimization goal. In this case, the values for the minimum dimensions which the cross-section
optimization goal is to find the optimal dimensions of the needs to have.
girder cross section to achieve the minimum mass of the
girder for the constant length and loading capacity. Stresses
in the girder must be lower than the allowed stresses for the

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3 DEVELOPMENT OF CAD AND NUMERICAL MODELS where the geometrical and parameter variation are natural"
[17-19].
During the development of the 3D CAD model, the goal The parametric model of a bridge crane girder is
is not just to get the visualization of the design, but also to developed by using the CATIA software package. First, the
get a functional 3D CAD model. A functional 3D CAD 3D model of the bridge crane girder is developed by using
model can be developed by using parametric modelling. the geometrical and dimensional constraints. After the 3D
The term parametric design is associated with the model is developed, parametrization of design parameters,
parametric systems and it is defined as "a process of defined in Chapter 2 of this paper, can be carried out. An
designing with parametric models in a virtual surrounding example of the relation between the parameters is shown in
Fig. 3.

Figure 3 Relation between parameters

The finite element structural analysis via the Generative the first three or four modes are important in practical
Structural Analysis in the software package CATIA module applications [27]. For the bridge crane girder, only the first
is carried out by using the above-mentioned developed 3D mode is taken into account as a relevant one. This will reduce
CAD parametric model. The first step in the process of the the time of calculations (Fig. 5).
finite element structural analysis is to carry out the
discretization of the girder by using finite elements [20-26].
The second step is to apply the constraints. In this case,
the girder is supported at both ends. One end has all
translations fixed and all rotation allowed, the second end is
a movable support with all translations and rotations allowed
(Fig. 2a).
The third step in the process of the finite element
structural analysis is to apply the loads on the girder. All
loads from real working conditions must be applied to the
girder. The girder is loaded with their own weight, the weight
of the load which it is carrying and the weight of the winch.
The results of the finite element structural analysis,
carried out on the initial 3D CAD model, are the values of the
displacements and Von Mises stresses. These values will be
used as the constraints for optimizations (Fig. 4). Figure 4 Results of a static finite element analysis on the initial 3D model of a
As it has earlier been mentioned, one of the constraints bridge crane girder: a) vector of displacements, b) Von Mises stresses
should be the value for lateral torsional buckling. To get this
value, it is necessary to carry out a new structural analysis for Fig. 5a shows the deformation of the girder without
this case. The static analysis of lateral torsional buckling is lateral bracing during lateral torsion buckling loads. The
taken as a referent analysis. coefficient of deflection for this case is 0.324. Fig. 5b shows
The analysis of lateral torsional buckling in the CATIA the deformation of the girder with three lateral bracings. For
software package gives 10 modes of the torsional twist. Only this case, the coefficient of deflection is 4.45. It can be

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noticed that deformation is significantly bigger in the case - deflection:

where lateral bracings are not applied, i.e. girder will deform
because the coefficient of deflection is lower than 1. wd − w ≥ 0 (7)

where: σv - the tension on the extension limit, σu,p1 - maximal

tension in the upper flange, σu,p2 - maximal tension in the
lower flange, σu,r - maximal tension in the girders web, σs,r -
flexion tension in the girders web, σux - border tension on
buckling, υ - the level of security.
For resolving the cost function minimization problem,
the Eq. (4) with constraints, Eq. (5), Eq. (6) and Eq. (7),
which have a form of inequality cj = (b, t1, h, t) ≥ 0, j = 1, 2,,
…, m, and a penalty function method SUMT are used. With
the introduction of the penalty function here, a new cost
function is formed, Eq. (8) without limitations, and then the
function minimum is determined:

m
1
, t1 , h, t , r ) f (b, t1 , h, t ) + r ∑
Φ (b= (8)
j =1 c j = (b, t1 , h, t )

Figure 5 Deformation of the girder; a) without lateral bracing, b) with three lateral
bracings
To solve the problem, a previously made computer
program in FORTRAN was adjusted [29].
4 DEVELOPMENT OF AN OPTIMIZATION MODEL
4.1 The Mathematical Model 4.2 The Numerical Model

For the development of an optimization model, the The same problem was solved numerically, and for that
nonlinear SUMT (Sequential Unconstrained Minimization purpose, the CATIA module Product Engineering Optimizer
Technique) method was used. According to this method, the was used. The module has iterative methods that can be used
so-called penalty functions are introduced. In these for any parameter [30]. In this case, the so-called simulated
processes, approximation is carried out by adding the penalty hardening algorithm is used. This algorithm was chosen
member to the goal function in the area where constraints are because the goal function is unknown, and because this
not satisfied [28]. For the goal function, a girders mass is algorithm can avoid local minimums and find the global
selected, which has the following form: maximum. For this algorithm, the speed of convergence can
be chosen [31-33].
After the definition of the goal function, design
f (b, t1 , h, t )= (2b ⋅ t1 + h ⋅ t + a ⋅ c) ⋅ L ⋅ ρ ⋅ g (4)
parameters and constraints. The results of the optimization
can be presented in the form of diagrams for different
where: b, t1, h, t, a and c - are shown in Fig. 2, ρ – the specific combinations of design parameters. (Fig. 6 and Fig. 7). Fig.
mass of steel, g - speed of gravity. 6a shows the changes of the goal function in the form of the
The constraints that the design should meet: value of mass for all iterations. In the same figure, a diagram
- flanges: of the best solution (the best value of the goal function) is
also shown. Fig. 6b shows the changes of the height of the
σ v − υ ⋅ σ u , p1 ≥ 0 web and the deviation of the values of the deflection from the
σ v − υ ⋅σ u, p2 ≥ 0 allowed values during the iteration process. It can be noticed
(5) that when increasing the values for the height of the web,
t1 − 1.2t ≥ 0 deviation is going close to zero, which means that the
2t − t1 ≥ 0 deflection has lover values. From Fig. 7a, it can be noticed
that the maximal deflection is 15.96 mm, which means that
- the web: the constraints for deflection are fulfilled.
Furthermore, from Fig. 7b, it can be noticed that
maximal stresses occur at the lover part of the girder and that
σ v − υ ⋅σ u, r ≥ 0
the maximal value is 82.4 MPa, which is lower than the
σ ux − υ ⋅ σ s , r ≥ 0 constraint of 160 MPa.
(6)
σ v − σ ux ≥ 0
t −5 ≥ 0

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Figure 6 Parameter changes during the iteration process a) relation between the current and best mass of the girder b) relation between deflection and the height of the web

5 RESULTS

Fig. 8a shows diagrams of the dependency of the mass of

the girder to the number of lateral bracing for different
lengths of the girder. It can be noticed that the number of
lateral bracing does not have a significant effect on the mass
of the girder. This is an important fact, because for the lengths
of 16 m, 20 m, and 25 m of the girder, the optimization
algorithm could not find the solution without using lateral
bracing. The constraint for lateral torsional buckling could
not be fulfilled. After adding only one lateral bracing at the
middle of the girder, optimization was carried out
successfully.
Fig. 8b shows the correlation between the mass of the
girder and the allowed deflection for the length of 16 m, the
free length of torsional buckling of 4 m and the ratio of h/t =
120. The calculation is carried out for the loads of 100 kN
and 200 kN and the ratios of L/f = 1000, 950, 900, 850, 800,
850. By increasing the value of the allowed deflection, the
needed stiffness of the girder is reduced, which means that
the girder can have smaller dimensions and a lower mass.
Figure 7 Values after optimization; a) deflection, b) Von Mises stress

Figure 8 Mass of the girder; a) for different lengths of the girder and a different number of laterals bracing for the load of 200 kN, b) in correlation to the allowed deflection for a
length of 16 m, the free length of torsional buckling of 4 m and the ratio of h/t = 120

Fig. 9a shows the optimal values of the mass of the girder Optimizer are the same as the results obtained by the SUMT
for the lengths of 12 m and 16 m and the loads of 50, 100, (Sequential Unconstrained Minimization Technique)
160, 200, 250 and 320 kN. These values of mass result from method.
the structural optimization of the software CATIA. It is The h/t ratio also has an important effect on the mass of
important to notice that the results obtained by the structural the girder. For the same length of the girder, the same free
optimization in the CATIA module Product Engineering length of the torsional buckling and the same loads, a

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different mass can be obtained by changing the height and Girders with a high value of the h/t ratio have a problem
thickness of the web. An increase of the h/t ratio has a because buckling can occur. It is necessary to check the
positive impact on the deflection of the girder, and the girder for buckling and if necessary, to add an additional
constraint for the allowed deflection was fulfilled faster. vertical and/or horizontal bracing on the web.
Fig. 9b shows the correlation between the mass of the
girder and the h/t ratio for the load of 200 kN, the allowed
deflection L/1000 and the free length of the buckling of 4 m.

Figure 9 Mass of the girder; a) in correlation to the load of the crane for ratio h/t = 120 and free length of buckling of 4 m, b) in correlation to the ratio h/t for load of 200 kN,
allowed deflection L/1000 and free length of buckling of 4 m

6 CONCLUSION tool which is easy to use and which gives a lot of useful data
about the behavior of the design for different input
The goal of the optimization process carried out in this parameters (dimensions, loads etc.). When using this module,
paper was to find the minimal value of the mass of the bridge it is possible to design lighter and more economical designs.
crane girder designed as a welded I-profile. The mass of the Additionally, an important advance of this module lies in its
girder depends on the input parameters such as the length of fast calculation properties, which reduce the time of the
the girder, the load of the bridge crane, the allowed deflection design or redesign processes. The task which needs to be
and the ratio between the height and the thickness of the carried out by engineers is to develop an optimization model,
girder web. Optimization is carried out for different run the calculation, and analyse the results. Engineers need
combinations of the above-mentioned input parameters. to have some real life experience to precisely develop the
For a numerical analysis and optimization, the CAD/CAE optimization model and to analyse the results in the right
system CATIA V5 was used. A structural numerical analysis manner.
is the first step that needed to be carried out to start with the A disadvantage of this module is the need to have
optimization process. Using the structural numerical analysis computers with height characteristics, the so-called
data for displacements, the stresses and buckling coefficients workstations. With workstations, it is possible to develop
can be obtained at all points of the design. With the help of advance optimization models and to carry out calculations
computers and software, the calculation process is fast. with a small amount of errors.
Additionally, it is easy to control the values of all parameters The optimization methodology developed in this
and to obtain certain conclusions about the behaviour of the research can be used for the optimization of similar designs.
design for the applied constraints. The mass of the girder can be additionally minimized by
It is important to notice that for a successful optimization analysing others shapes of the girder cross section. For the
of the design, it is not enough to know how to work with results presented in this paper, it can be noticed that the
computer software, but it is also very important to understand material at the end of the girder is not used properly. It is
the real constraints of the design during exploitation. This possible to remove some of the material at those places of the
knowledge is important if someone wants to develop an girder. A girder can have a different height at the ends and at
optimization model which is very similar to the real design. the middle.
It is important to know how design is supported, where the
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https://doi.org/10.21833/ijaas.2019.04.009 International Journal of Engineering & Technology, 5(1), 20-
[17] Saric I., Pervan N., Muminovic A., & Colic, M. (2018). 26. https://doi.org/10.14419/ijet.v5i1.4912
Development of Integrated Intelligent Cad System for Design
of Shafts. Tehnički vjesnik, 25(Supplement 1), 99-104.
https://doi.org/10.17559/TV-20170521194820 Authors’ contacts:
[18] Saric, I., & Muminovic, A. J. (2018): Development of
integrated intelligent CAD system for synthesis and stress- Nedim Pervan, PhD, Assistant Professor
deformation analysis of pressure vessels. International Journal University of Sarajevo, Faculty of Mechanical Engineering,
of Engineering & Technology, 7(1). Vilsonovo setaliste no. 9,
71000 Sarajevo, Bosnia and Herzegovina
https://doi.org/10.14419/ijet.v7i1.8666
Tel.: +387 33 729 800
[19] Pervan, N., Muminovic, A. J, Muminovic, A., & Delic, M. [email protected]
(2019). Development of Parametric CAD Model and Structural

192 TECHNICAL JOURNAL 14, 2(2020), 186-193

 Nedim Pervan et al.: Dimensional Structural Mass Optimization of Welded I-Profile Bridge Crane Girder

Adis J. Muminovic, PhD, Assistant Professor

(Corresponding author)
University of Sarajevo, Faculty of Mechanical Engineering,
Vilsonovo setaliste no. 9,
71000 Sarajevo, Bosnia and Herzegovina
Tel.: +387 33 729 800
[email protected]

Elmedin Mesic, PhD, Associate Professor

University of Sarajevo, Faculty of Mechanical Engineering,
Vilsonovo setaliste no. 9,
71000 Sarajevo, Bosnia and Herzegovina
Tel.: +387 33 729 800
[email protected]

Mirsad Colic, PhD, Full Professor

University of Sarajevo, Faculty of Mechanical Engineering,
Vilsonovo setaliste no. 9,
71000 Sarajevo, Bosnia and Herzegovina
Tel.: +387 33 729 800
[email protected]

Vahidin Hadziabdic, PhD, Associate Professor

University of Sarajevo, Faculty of Mechanical Engineering,
Vilsonovo setaliste no. 9,
71000 Sarajevo, Bosnia and Herzegovina
Tel.: +387 33 729 800
[email protected]

TEHNIČKI GLASNIK 14, 2(2020), 186-193 193