A novel topology optimization method of welded box-beam structures motivated by low-carbon manufacturing concerns

This paper proposes a simple and effective topology optimizer to get the best-possible layout scheme of welded box-beam structures that emit less greenhouse gases (GHGs) in manufacturing stage than has been common practice. Firstly, a cradle-to-gate approach is adopted to identify the relationship between the GHGs emission of welded box beams in manufacturing stage and the variables of topology optimization (thickness and coordinates of the stiffener plates). Then, a low-carbon design framework is built to realize the simultaneous handling of GHGs emission reduction and structure layout reconfiguration. Unlike the conventional optimization methods, the proposed method releases more flexibility in representing geometry and topology change during the optimization procedure. As a result, stiffener plates are allowed to move freely within the box beams so as to form a global optimized layout solution. The proposed method is finally applied to the re-design of a welded sliding beam of the hydraulic press machine, on which the numerical analyses conducted exemplify the GHGs emission reduction and structural performance enhancement, and therefore is a good choice for the low-carbon design of large-scale welded engineering structures.