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Review Paper | Structural Engineering | Volume 15 Issue 8, August 2026 | Pages: 553 - 560 | India
Finite Element Analysis and Design Evaluation of Castellated Beams Fabricated through Rapid Metal Development: A Comparative Study of Sinusoidal, Circular and Hexagonal Web Openings
Abstract: Castellated beams are increasingly adopted in long-span steel structures because web perforation permits depth expansion without a corresponding increase in self-weight. However, perforations modify shear flow, induce Vierendeel action and concentrate stresses near web-posts; therefore, refined numerical assessment is needed before design adoption. This paper converts a dissertation-stage study on castellated beams and Rapid Metal Development (RMD) into a journal-style research article. A 6 m simply supported steel beam was modelled in ANSYS and compared for three opening geometries: sinusoidal, circular/cellular and hexagonal. The analysis considered total deformation, equivalent von-Mises stress, normal elastic strain and equivalent elastic strain. The sinusoidal beam recorded a maximum deformation of 4.2418 mm and equivalent stress of 3.3629 MPa, compared with 4.30 mm and 3.50 MPa for circular openings and 5.249 mm and 5.121 MPa for hexagonal openings. Relative to the hexagonal beam, the sinusoidal configuration reduced deformation by 19.19% and equivalent stress by 34.33%. The results indicate that smooth opening geometry can reduce stress concentration and improve serviceability response. The study also demonstrates how RMD-oriented fabrication methods can improve dimensional tolerance, cutting consistency and weld quality, making castellated beams more suitable for industrialized steel construction.
Keywords: castellated beam, cellular beam, sinusoidal opening, hexagonal opening, Rapid Metal Development, ANSYS, finite element analysis, web opening, Vierendeel action, steel structures
How to Cite?: Suraj Potdar, Girish Joshi, "Finite Element Analysis and Design Evaluation of Castellated Beams Fabricated through Rapid Metal Development: A Comparative Study of Sinusoidal, Circular and Hexagonal Web Openings", Volume 15 Issue 8, August 2026, International Journal of Science and Research (IJSR), Pages: 553-560, https://www.ijsr.net/getabstract.php?paperid=SR26807213154, DOI: https://dx.doi.org/10.21275/SR26807213154