Development of Cast Modular Components for Steel Construction

CMS提案0324664PI: Fleischman， arizona提出了一项重大倡议，旨在通过使用模块化铸造组件来提高美国钢结构的可靠性和经济性。该倡议代表了美国钢结构协会（AISC）、美国钢铁创始人协会（SFSA）和亚利桑那大学（UA）研究人员之间的统一努力。成立了一个任务小组，钢铁创始人/钢铁建筑（SF/SC），带头开展这项工作。除了上面列出的AISC和SFSA的共同pi外，SF/SC由SFSA铸造成员、AISC制造成员和执业结构设计工程师组成。自2002年初以来，SF/SC一直在举行会议，就共同感兴趣的领域展开讨论。该活动将涉及确定结构钢的应用，其中模块化结构可以：(1)提高组件的经济性和/或可靠性；(2)消除困难或昂贵的制造和/或困难或危险的安装；并且，(3)由于实际原因，允许在以前未探索的情况下使用钢结构。将构思铸造模块化组件，包括更高效的细节/部分和全新的形式，强调经济、可建造性和满足建筑需求。这些形式的Alpha原型将通过广泛的参数研究来开发，用于评估几何形状、材料或开发特殊功能。这些参数研究本质上是分析性的：结构性能将通过有限元实体建模来评估，而浇注性将通过凝固建模来评估。在UA的结构分析小组和SFSA的铸造分析小组之间，将通过电子交换实体模型数据的迭代程序获得最佳形状。一旦设计得到优化，SFSA团队将铸造全尺寸的物理原型。使用合适的周围钢构件，AISC团队将把原型制造成结构组件。这些步骤还允许SFSA和AISC团队评估与铸造和制造过程的易用性，完整性和经济性相关的制造问题。原型机将在UA综合计算和实验实验室（ICEL）的全尺寸反应框架中进行测试。这些验证测试将用于确定细节或确定结构性能方面的进一步挑战，以便在测试原型中解决。这种方法的发展铸造模块化形式已被PI在他的NSF职业研究取得了巨大的成功。在原型成功验证测试后，AISC团队将确定合适的实施地点，并对安装问题进行评估。该团队在建筑丰富的芝加哥地区的强大存在将促进概念验证的最后一步。每项发展进程都将以全面的经济分析结束；资格预审/编纂，以及SF/SC的推广/营销工作。行业参与将包括母公司AISC和SFSA及其几个行业成员。AISC、SFSA及其成员将贡献时间和成本分担，包括：实物资金、材料捐赠和与实验项目标本创建相关的人工成本；在概念和原型开发方面的工程；具备进行全面经济评估和可行性研究的专业知识；技术转让活动，包括资格认证、代码开发、营销和推广。仅前两项的货币价值：实物资金（估计每个行业组织每年6000美元）和标本材料和人工捐赠（每个行业组织每年6000美元）在项目的3年期间将不低于72,000美元。与此活动相关的重大工程努力将使工业贡献达到16.8万美元。知识价值。该项目将促进钢结构领域的知识，更好地理解构件之间的力流；通过方法、知识基础和技术的交流，实现跨领域交流。该项目探索了一种创造性的方法来建造、制造和设计钢结构。为了实现这些目标，该项目将推进最先进的制造与分析模拟的集成，这种集成将在学术界和工业界之间完成。影响范围：项目将直接影响国内两大重点行业：钢结构行业和铸钢件行业，并发展合作伙伴关系。两个代表机构AISC和SFSA的参与证明了行业的兴趣，包括组成联合行业委员会和如上所述的财政支持。项目成果一旦实现，将产生新的高效、安全、经济的连接设计，并推动钢结构行业向模块化结构发展。该项目将支持2名研究生，他们将通过研究和与行业从业者的互动来接受教育。研究成果将直接传播给行业从业者。

Development of Cast Modular Components for Steel Construction, CMS proposal 0324664PI: Fleischman, ArizonaA major initiative is proposed to improve the reliability and economics of steel construction in the United States through the use of modular cast components. The initiative represents a unified effort between the American Institute of Steel Construction (AISC), the Steel Founder's Society of America (SFSA) and researchers at the University of Arizona (UA). A task group, Steel Founders / Steel Construction (SF/SC), has been organized to spearhead this effort. In addition to the AISC and SFSA staff listed above as co-PIs, the SF/SC is comprised of SFSA foundry members, AISC fabricator members, and practicing structural design engineers. SF/SC has been meeting since early 2002 to initiate discussion on areas of common interest. The activity will involve identifying structural steel applications where modular construction can: (1) improve economy and/or reliability of a component; (2) eliminate difficult or costly fabrication and/or difficult or dangerous erection; and, (3) permit the use of steel construction in situations previously unexplored for practical reasons. Cast modular components will be conceived, including more efficient details/sections and altogether new forms, with an emphasis on economy, constructability, and meeting architectural need. Alpha prototypes for these forms will be developed through extensive parametric studies used to evaluate geometry, material or develop special features. These parametric studies will be analytical in nature: structural performance will be evaluated through finite element solid modeling while castability will be evaluated through solidification modeling. Optimal shapes will be obtained through an iterative procedure involving electronic exchange of solid model data between the structural analysis team at UA and the casting analysis team at SFSA. Once designs have been optimized, the SFSA team will cast full-scale physical prototypes. Using the appropriate surrounding steel members, the AISC team will fabricate the prototypes into structural assemblages. These steps also allow the SFSA and AISC teams to evaluate manufacturing issues related to the ease, integrity and economy of the casting and fabrication processes. The prototypes will be tested in the full-scale reaction frame at the UA Integrated Computation and Experimentation Laboratory (ICEL). These verification tests will be used to qualify a detail or identify further challenges in structural performance to be addressed in a beta prototype. This approach to the development of cast modular forms has been used with great success by the PI in his NSF CAREER Research. Following successful verification testing of a prototype, the AISC team will identify appropriate implementation sites and the erection issues will be evaluated. The team's strong presence in the construction rich Chicago-land area will facilitate this final step in the proof of concept. Each development process will conclude with a comprehensive economic analysis; prequalification/codification, and outreach/marketing efforts by the SF/SC. Industry involvement will involve both the parent organizations AISC and SFSA and several of their industry members. AISC, SFSA and their members will contribute time and cost sharing including: in-kind funds, donations of material and labor costs associated with the creation of specimens for the experimental program; engineering in terms of conception and development of the prototypes; expertise in performing comprehensive economic evaluations and feasibility studies; technology transfer activities including qualification, code development, marketing and outreach. The monetary value of the first two items alone: in-kind funds (estimated @ $6K/yr per industry organization) and donation of material and labor for specimens (also $6K/yr per ind. org.) will not be less than $72,000 for the 3-year duration of the project. The significant engineering efforts associated with this activity will place the industry contribution at $168,000. Intellectual Merit. The project will advance knowledge within the field of steel construction in better understanding force flow between components; and across fields by exchange of approaches, knowledge base, and technology. The project explores a creative approach to building, manufacturing and design of steel structures. To accomplish these goals, the project will advance the state-of-the-art in integrating manufacturing with analytical simulation, and this integration will be accomplished between academia and industry. Broader Impact: The project will directly impact two key domestic industries: the steel construction industry and the steel casting industry, and develop partnerships among them. Industry interest is evidenced by the participation of the two representative institutes, AISC and SFSA, including the formation of a joint industry committee and financial support as indicated above. The project results, when realized, will result in new efficient, safer and economical connection designs and move the steel construction industry toward modular construction. The project will support 2 graduate students, who will be educated through research and interactions with industry practitioners. Research results will be disseminated directly to industry practitioners.