Cross section shape optimization of wire strands subjected to purely tensile loads using a reduced helical model

Abstract

This paper introduces a shape optimization of wire strands subjected to tensile loads. The structural analysis relies on a recently developed reduced helical finite element model characterized by an extreme computational efficacy while accounting for complex geometries of the wires. The model is extended to consider interactions between components and its applicability is demonstrated by comparison with analytical and finite element models. The reduced model is exploited in a design optimization identifying the optimal shape of a 1 + 6 strand by means of a genetic algorithm. A novel geometrical parametrization is applied and different objectives, such as stress concentration and area minimization, and constraints, corresponding to operational limitations and requirements, are analyzed. The optimal shape is finally identified and its performance improvements are compared and discussed against the reference strand. Operational benefits include lower stress concentration and higher load at plastification initiation.