WEB BUCKLING OF CASTELLATED BEAMS

Sabarish J., and Biju V.

Department of Civil Engineering College of Engineering Trivandrum sabarish_j@yahoo.co.in, biju_vasudevan@yahoo.co.in

Abstract Finite element analysis of web post buckling in castellated beams is studied by using ANSYS. A comprehensive finite element investigation on steel beams with various shapes and sizes is reported in this paper based on web post buckling. Inelastic finite element approach was used to predict the buckling loads. A parameter study was conducted based on web post width and the effect of various openings is described in this paper. Keywords-Castellated beam, web openings, web post buckling.

tee-sections above and below the holes yielded in a manner similar to that of a plain webbed beam, although the spread of yield towards the central axis was stopped by the presence of the holes by which time the two throat sections had become completely plastic in compression and in tension. B. Lateral-Torsional Buckling Non-composite castellated beams are more susceptible to lateral-torsional buckling than composite beams due to lack of lateral support to the compression flange. The lateral torsional buckling behaviour of castellated beams is similar to that of plain webbed beams. The holes had a significant influence on lateral-torsional buckling behaviour. C. Formation of Vierendeel Mechanism Vierendeel bending is caused by the need to transfer the shear force across the opening to be consistent with the rate of change of bending moment, in the absence of local or overall instability, hexagonal castellated beams have two basic modes of plastic collapse, depending on the opening geometry. The failure is dependent on the presence of a shear force of high magnitude in the holes through span. D. Rupture of the Welded Joint in a Web Post Rupture of a welded joint in a web-post can result when the width of the web-post or length of welded joint is small. This mode of failure is caused by the action of the horizontal shearing force in the web-post, which is needed to balance the shear forces applied at the points of contra flexure at the ends of the upper I-section. E. Shear Bucking of a Web Post The horizontal shear force in the web-post is associated with double curvature bending over the height of the post. In castellated beam one inclined edge of the opening will be stressed in tension, and the opposite edge in compression and buckling will cause a twisting effect of the web post along its height.

I. INTRODUCTION Castellated beams are nowadays commonly used as structural members in many countries. Castellated beams are manufactured by cutting a wide flange beam in a zigzag pattern along the web. This is usually done with an automated computer-controlled plasma torch, separating the two halves, and then welding the web post back together at the high points with an automated submerged arc welding process. This process increases the depth of the beam by approximately 50%, therefore increasing the strength and stiffness by 40%. By forming a standard rolled I-section into a castellated beam, a section is obtained with an elastic section modulus and moment of inertia higher than that of the rolled section, at no increase in mass. A case for castellation can only be made when a high level of stiffness is required (i.e. a large inertia). The principal advantage of castellation is the increase in vertical bending stiffness. Castellated beams, because of their high strength-to-weight ratios and their lower maintenance and painting costs, can sometimes advantageously replace built-up girders. The disadvantage is that due to the presence of the holes in the web, the structural behavior of castellated beams will be different from that of the plain webbed beams. Because of different possible modes of failure or even new modes also, they are highly indeterminate structures, which are not susceptible to simple methods of analysis. The re-entrant corners at the openings give rise to stress concentrations and limit the usefulness of castellated beams in situations where dynamic effects are severe. II. FAILURE MODES FOR CASTELLATED BEAMS

The mode of failure depends principally upon the beam slenderness, the geometry of the cut (height, breadth and spacing of the holes) and the type of loading. Six potential failure modes [1] are associated with castellated beams are: A. Formation of Flexure Mechanism This mode of failure can occur when a section is subject to pure bending. The span subjected to pure bending moment, the

Figure 1. Web post buckling

F. Compression Buckling of a Web Post This mode of failure is similar to the crippling of the web in a plain webbed beam. It can occur in regions near concentrated loads or reaction forces. III. FORMULATION OF RESEARCH OBJECTIVE Available literatures does not deal with the characteristics of web post width under web buckling failure mode for steel beams with web opening of various shapes and sizes. This paper investigates the possibility of stability loss due to web post buckling of castellated beam by varying the web post width, since the castellated beams are relatively slender and have web openings, which have an influence on their resistance. The major failure modes of castellated beams are web post buckling [2]-[3] and lateral-torsional buckling. The principal geometric parameters differentiating in castellated beams are associated with slenderness of the web post. Slenderness of the web-post is related to aspect ratio (whether measured as the ratio of opening height to minimum width or average width (h0/e)) and a higher ratio of opening height to web thickness (h0/tw). The failure modes mainly depend on area of openings, location of opening, length of the tee-section above and below the opening, opening depth and type of opening. A comprehensive finite element investigation on steel beams with web opening of various shapes and sizes is conducted. Investigation of web post buckling includes parametric study and effect of various web openings in castellated beams. IV. FINITE ELEMENT ANALYSIS USING ANSYS Finite element software ANSYS is used for the analysis of castellated beams. The three main stages in the analysis of the software are pre processing stage, solution phase and post processing stage. For the purpose of the web-post buckling study, three dimensional finite element models are developed. The problem chosen is castellated beam subjected to a concentrated load along the mid span of the beam. Castellated beams are modelled [2], and dimensions are shown in Table I.
TABLE I. GEOMETRY OF C ASTELLATED BEAMS
Stiffener Plate Thickness (mm)

Figure 2. Provision of hexagonal opening

Four noded shell elements (SHELL 181) from the ANSYS element library are used to model the castellated beam. Structural steel is used as the material for the analysis of castellated beams. Youngs modulus, E is set to 2x105 N/mm2 and Poissons ratio as 0.3. The yield stress of the flange is 345.6 MPa and for web 352.9 MPa. Both geometric and material nonlinearity are incorporated in the analysis. A nonlinear buckling analysis is a nonlinear static analysis including large deformation effects. Hence geometric nonlinearity is also incorporated in the analytical procedure. The solution procedure used in nonlinear analysis is NewtonRaphson method. The material nonlinearity is modelled using ideal elasto-plastic assumption. The material relationship has been modelled as a Von-Mises material with isotropic hardening law. Stiffeners are provided at support to avoid loss of stiffness. Simply supported end condition is assumed by arresting the displacement along y direction at both ends. The movement along z direction is arrested for one of the support. Also to have stability the displacement of one node at support as well as at centre of loading point is arrested along x. The loading points are provided with adequate lateral support. By giving proper thickness the model is meshed and the meshed models are shown in Fig. 3.

Figure 3. Castellated beam FEM model-1 and model-2

Castellated Beam

L (mm)

d (mm)

(mm)

(mm)

(mm)

Model-1 Model-2

2480 1850

380.5 380.5

3.56 3.56

4.59 4.59

66.9 66.9

9.53 9.53

The models were based on its span and housed six to eight hexagonal openings. Detail of provision of hexagonal opening is modelled [2] as shown in Fig. 2.

As the validation part, the buckling of web post between openings is analyzed in two beams [2]. Elastic buckling modes have occurred under different moment to shear (M/V) ratios around web openings. The tensile forces below the openings will be different due to the moment gradient (i.e. shear), and this difference is equal to the horizontal shearing force in the web-post. This horizontal shear occurs at the minimum section of the web-post i.e. at mid-depth. The combined shear and bending is unlikely to cause elastic action in the post, thus causing mid-depth yield which is considered to be a feasible failure mode. Web post buckling of model-1 and model-2 is shown in Fig. 4.

to web thickness (e/tw). The change of web-post width (e) affects corresponding change in yielding mechanism load and critical buckling load. The variation of predicted buckling loads and yield mechanism load with aspect ratio is shown in Table III.
TABLE III. VARIATION OF PREDICTED LOADS WITH ASPECT R ATIO
Increased Actual web-post width [2] e= 77.8mm Pcr (kN) Py (kN) Decreased web-post width e= 72.8mm Pcr (kN) Py (kN)

Figure 4. Web post buckling of model-1 and model-2

Time history post processing is used to get load deflection data. From the load deflection data, web-post buckling load of castellated beam model-1 and model-2 is determined and is shown in Table II.
TABLE II. COMPARISON OF WEB POST B UCKLING LOAD
FEA value using NASTRAN (kN) [2] Predicted FEA value using ANSYS (kN) % Error with
Experimental

Beam Model

web-post width e= 82.8mm Pcr (kN) Py (kN)

Model1 Model2

81.9 97.2

85.6 107.5

82.2 98.4

86.7 108.8

82.5 98.9

89.1 110.9

Beam model

Experimental Value (kN) [2]

Value

% Error with FEA Value

Mode -1 Model -2

84.4 94.8

81.3 84.1

82.2 98.4

2.6 3.8

1.1 17

The variation of Pcr/Py depends on aspect ratio and web post width to web thickness (e/tw). All predicted buckling loads are higher than the yielding mechanism load. Therefore the low value of the ratio Pcr/Py gives the susceptibility to web-post buckling. The variation of Pcr/Py with aspect ratio is shown in Table IV.
TABLE IV. VARIATION OF Pcr /Py WITH ASPECT RATIO Aspect Ratio (ho/e) 3.21 3.42 3.66 Model-1 Pcr/Py 0.96 0.95 0.93 Model-2 Pcr/Py 0.91 0.90 0.89

The FEA and experimental values from literature [2] is validated with predicted FEA values using ANSYS. The prediction of [2] does not match with that of ANSYS. This may be due to the assumed restraint conditions at the top and bottom of the web-post. V. PARAMETRIC STUDY OF WEB POST BUCKLING The principal geometric parameters differentiating in castellated beams are associated with slenderness of the web post. Slenderness of the web-post is related to aspect ratio (whether measured as the ratio of opening height to minimum width or average width (h0/e)) and a higher ratio of opening height to web thickness (h0/tw). A. Based on Aspect Ratio (h0/e) In castellated beams, shear stress is reduced due to the stress concentration around the web openings. When the shear is less, rapid widening occurred at the mid-depth and is considered to be feasible failure mode called web post buckling. The rotation of the tee-section web associated with the flange rotation produced out-of-plane displacements at the opening centerlines. This displacement is prevented by the boundary conditions used in FEM model. Thus a yield mechanism may be formed by the development of four plastic hinges at each end of the uniform tee-sections above and below of the opening. The load on the beam corresponding to yielding mechanism is denoted as (Py). The load corresponding to initiate web buckling process is called critical load (Pcr). Susceptibility to web-post buckling is indicated by a low value of the ratio of Pcr/Py. Reference [2] gives the aspect ratio (h0/e). So as a part of parametric study, two more set of beams were considered, with relevant parameters varied i.e. the ratio of hole height to minimum web-post width (h0/e) and the ratio of web post width

Graphical results for three set of geometries are presented in Fig. 5. It shows that when the web-post width is increased or decreased, beam undergoes large predicted buckling load with corresponding yielding mechanism load.

Figure 5. Variation of predicted buckling to predicted yield loads

From the graph, variation of predicted buckling to the predicted yield give rise to economically good prediction of the strength of the beams influenced by web stability. B. Based on Hole Height to Web Thickness (h0/tw) The variation of critical web post buckling strength and ultimate shear strength due to variation in thickness is shown in Table V.

TABLE V. VARIATION OF PREDICTED LOADS WITH HOLE HEIGHT TO WEB THICKNESS (h0/tw) Decreased web Beam Model thickness tw= 2.56mm Pcr (kN)
Model1 Model2

TABLE VI. COMPARISON OF AREA PRESENT IN THE WEB

Increase Web-Post Actual Web-Post Width e= 77.8mm
Model-1 Model-2

Decrease WebPost Width e= 72.8mm

Model-1 Model-2

Decreased web thickness tw=3.06mm Pcr (kN) 78.9 85.4 Py (kN) 81.4 92.4

Actual web thikness [2] tw=3.56mm

Increased web thickness tw =4.06mm Pcr (kN) 82.9 107 Py (kN) 93.8 116

Hole Openings

Width e= 82.8mm
Model-1 Model-2

Hexagonal Circular Rectangular

64.08 63.13 46.86

64.43 63.48 47.38

65.21 64.68 48.00

65.55 65.02 48.5

66.34 66.20 49.12

66.66 66.52 49.62

Py (kN) 77.7 70.9

Pcr (kN) 82.2 98.4

Py (kN) 86.7 108

77.1 70.8

It is generally expected that the shapes of the web openings are critical in the structural behavior of perforated sections. The finite element models of circular and rectangular opening are shown in Fig. 7 and Fig. 8.

Further increase in web thickness will result in flange failure. Both critical web post buckling strength and ultimate shear strength increases with increase in thickness of web post. At minimum thickness, the critical web post buckling strength and ultimate shear strength occurred at same load. The variation of predicted loads with ratio of opening height to web thickness in model-1 and model-2 are shown in Fig. 6.

Figure 7. Castellated beam FEM model-1 and model-2 (Circular opening)

Figure 6. Variation of predicted loads with ratio of opening height to web thickness in model-1 and model-2

Figure 8. Castellated beam FEM model-1 and model-2 (Rectangular opening)

EFFECT OF VARIOUS OPENINGS IN CASTELLATED BEAM The primary structural behavior of steel beams with opening of various shapes and sizes are examined. It is found that all steel beams with large web openings of various shapes subjected to important parameter in assessing the structural behavior of perforated sections is the length of tee sections above and below the web opening which controls the magnitude of local Vierendeel moments acting on the teesections [4]. Based on the finite element models established for steel beams with hexagonal openings, a comprehensive parametric study is carried out to investigate and compare the load carrying capacities of steel beams with web openings of circular and rectangular shapes having six to eight openings. Hexagonal, circular and rectangular openings are provided based on web post width. Two conditions are considered, (i) without change in the web post width (e) of the model-1 and model-2, (ii) with change in the web post width (e) of the model-1 and model-2. The web openings are provided without considering the area of holes. Comparison of the area of material present in the web for various shapes of web openings is shown in Table VI.

VI.

Due to the change in web post width (e), the location of the web opening is varied. Failure modes are common among all these beams with web openings of various shapes depending on the loading and support conditions of the beams and also locations of the web openings along the beam length. Comparison of predicted loads with variation of web opening is shown in Table VII.

TABLE VII. COMPARISON OF PREDICTED LOADS WITH VARIATION OF WEB OPENING

Increased webpost width Beam Model e= 82.8mm P
cr

Actual webpost width [2] e= 77.8mm P

cr

Decreased webpost width e= 72.8mm P

cr

P
y

P
y

P
y

(kN)
Model-1 (Hexagonal) Model-2 (Hexagonal) Model-1 (Circular) Model-2 (Circular) Model-1 (Rectangular) Model-2 (Rectangular)

(kN)

(kN)

(kN)

(kN)

(kN)

81.9 97.2 83.1 83.4 34.5 39.1

85.6 107.5 92.0 115.2 39.7 46

82.2 98.4 83.4 83.6 37.86 39.9

86.7 108.8 99.5 107.1 40.53 44.4

82.5 98.9 83.5 83.6 36.6 37.5

89.1 110.9 100.5 115.5 41.2 42.8

Figure 10. Variation of aspect ratio in model-1 and model-2 (Circular opening)

From Table VII, hexagonal opening carry more predicted load when web post width (e) decreases. This is due to, length of tee section above and below the opening controls the magnitude of local Vierendeel moments acting on the tee sections. Circular opening have high ultimate load carrying capacity due to the less in area of opening and opening depth. Models of rectangular opening show very poor performance at predicted loads since the area of web opening is more. The load-deflection curves of the beams with web openings of various shapes at different web post width are shown in Fig. 9 to Fig. 11. The curves may be divided in to three different parts, namely, (1) initial linear elastic deformation, (2) nonlinear deformation, and (3) ultimate stage near failure. The non-linear deformation stage indicates the degree of plasticity propagation at critical cross section of the tee section, and also progressive redistribution of loading from the low moment side to the high moment side of the perforated section. All the loaddeflection curves of perforated sections with various web openings of various shapes are shown to be similar.

Figure 11. Variation of aspect ratio in model-1 and model-2 (Rectangular opening)

From the graph, as web post width decreases, the corresponding predicted buckling load and yielding mechanism load increases due to the decrease in area of corresponding web openings. In case of rectangular opening, the length of the tee section above and below the opening increases the corresponding increase in the local Vierendeel moment acting at the tee-sections. VII. CONCLUSION

Based on the analytical study A non- linear static analysis finite element study is performed on castellated beams under web post buckling mode, using the ANSYS package. Increase in web post width (e), result in increase of predicted buckling load to yielding mechanism load. As the web thickness tw increases, the corresponding predicted buckling load and yielding mechanism load increases. The change in type of openings will result in variation of structural behaviour of beams. Circular openings will have high load carrying capacity. As web post width decreases, the corresponding predicted buckling load and yielding mechanism load increases due to the decrease in area of web openings. The length of the tee section above and below the opening increases the corresponding increase in the local Vierendeel moment acting at the tee-sections. REFERENCES
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Figure 9. Variation of aspect ratio in model-1 and model-2 (Hexagonal opening)

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