Approach for Automated Design of Metal Pergola … CAD/CAM Software TopSolid.v.6.15 Ventsislav Dimitrov, Mariyana Ivanova, Rumen Yankov, Nikolay Nikolov Abstract— The article proposed

International Journal of Scientific & Engineering Research Volume 7, Issue 4, April 2016ISSN 2229-5518

IJSER © 2016http://www.ijser.org

Approach for Automated Design of Metal Pergolacovered with Aluminum Composite Panels by

using CAD/CAM Software TopSolid.v.6.15Ventsislav Dimitrov, Mariyana Ivanova, Rumen Yankov, Nikolay Nikolov

Abstract— The article proposed a detailed methodology for the design of rights, decorative, standing metal pergola, covered withaluminum composite panels, representing ending architectural solution of an office building Class A (-) prepared by Aruid - Panayotovi - sieSD Rousse. For the design of the structure is used system TopSolid.v.6.15, in combination with the module for FEM analysisTopSolid’CastorXpress. There have been strength calculations in endangered sections, through a combination of classical computationalmethods, using "Execute standard wizard" and strength - deformation check on Finite element method.

Index Terms— Pergola, Aluminum Composite Panels, FEM Analysis, Hot-rolled Profiles

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1 INTRODUCTION ergola is an architectural element that appears as anextension of a building or a terrace. It can be performed inall shapes and sizes [3],[4],[5].

The use of the metal pergolas is an elegant solution toincrease the useful space of the buildings. These are structureswith an array of design solutions for exterior design. For abeautiful and practical design are needed supporting columnsand beams. In the classic version of the basis of the Pergola areused rail fixing elements.

The roof part is formed by the broad elements which areplaced under a certain angle and orientation. As coveringelements are used PVC, polycarbonate panels, aluminumsiding composite panels, glass or HPL panels [3],[4],[5].

Depending on the slope, pergolas are straight and slanted.The first are more stable and allow coverage of a large area.Sloping usually fitted to existing buildings and are practicaland elegant solutions for bay windows and balconies.

Last but not least is the durability and longevity of thesubstructure defining, which is decisive for its installation [4].

Pergolas often lately and have decorative functions form anadditional volume of the buildings. They are used to give thecomplete cubic or cylindrical model, and rarely have atechnological purpose.

Pergolas with coating of composite panels are especiallyattractive solutions for business and administrative buildingsespecially in Class A. One of them, as is the case with thispergola, designed by architectural Bureau ARUID-PANAYOTOVI-S-IE SD, have a natural decorative –architectural expressed twist. She's right, built of welded steelprofiles skeletal structure and covered with a casing of

composite panels with textured imitation of wood-basedpanels. Aims to outline the contour of the top floor of thebuilding and give completeness. The design of this type ofpergolas is extremely complicated, especially from the point ofview of the aluminium cladding, due to the fact that eachsheet is performed with peculiar shapes and sizes and need tofit perfectly, to the other otherwise the effect is lost.

2. METHODOLOGY AND CONSISTENCY OF DESIGNThe methodology for the design of structures of this type

includes a set of design-computational works that areinterrelated and are carried out in a certain sequence [2],[5].

2.1 Introduction to architectural designIn the first place stands the need for detailed research and

analysis of source documents and in particular architecturalconcept (Aruid - Panayotovi - sie SD Rousse), which will beimplemented with the designed structure. Particular attentionin the analysis should be paid to the establishment of thescheme of pergola. If the results of the analysis constructorfind more rational decisions on the scheme of establishment orthe construction of the facility, these decisions must be agreedwith the architect and structural engineer, and then bereflected in project documents.

2.2 Choice of establishment schemeBased on facility-based on conducted analysis of

technological output documentation proposed by theconstructor accepts a construction engineer and architectbasing scheme or select and coordinate them with other morerational [2].

Score status of basic surfaces intended establishment -under existing metal structures or predetermined slabs of thebuilding to which can be welded rail fixing parts of the roofconstruction.

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· Ventsislav Dimitrov is Assistant Profesor of ManufacturingTechnology in Technical University of Sofia, Sliven Engineering-Pedagogical Faculty, Bulgaria, Europеan Union, E-mail: [email protected] Scientific interests include Cutting tools, Theory of Surface Plastic De-formation (SPD), High Speed Machining and Reliability of the Industrialsystems.

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2.3 Construction of the bearing elements of thestructure

The structure is built on a modular basis as a collection offarms. The individual parts are made of hot rolled profiles 2xU10 and hollow welded profiles K80x80x4. On farms is a meshof profiles K40x20x2 to which sets sail from composite panels.The devices are attached to the reinforced concrete belt by arcwelding to previously earned mounting plates. All elements ofthe substructure are treated with anti-corrosion coatingPROTEKTA [2].

2.4 Design of elements from substructure for thecladding of aluminium composite panels and preparethe components for it.

It is planned to be executed as a set of К40х40х2 as farms.They are welded directly to the bearing hot rolled profilesfrom the bearing metal construction. Elements of the enclosurecladding be established directly through profiles of theconsoles from profile and L30x30x1 and self drilling screwsDIN 7504P directly to them. The individual plates are thickand 25mm and joints between the sheets 20 mm.

2.5 Choice of technology and design of the route forthe installation of the facility.

The designed structure with composite cladding isprefabricated and transported on separate nodes.

3. DESIGN OF THE ELEMENTS

3.1 Selection of materials for manufacturing of striationMaterials for manufacturing of individual elements of the

pergola with cladding from aluminium composite panels areselected depending on the functional purpose fig.1 and Table1 [11]:

- fоr the basic elements of supporting steel constructionusing hot rolled sections:

Ø beams [10 - S235JRG2, according to EN 10025 (RSt37,2according to DIN 17100),

Ø capitals and farms K80x80x4 - DIN St50-2 (accordingto DIN 17100),

Ø ribs K60x60x3 - DIN St50-2,Ø mesh K40x40x2 - DIN St50-2.

- fоr consoles St 37-3 DIN 17100Before manufacturing the workpieces are verified. Control

includes checking the chemical composition and physical -mechanical properties– table 1 fault detection of the presenceof pores and cracks, control of dimensions. A necessary stagein the preparation of workpieces for mechanical treatment areand the appropriate heat treatment to them.

- for cladding from aluminum composite panels usedpanels type Durall 600 [10] - fig.2.

Due to their advantages composite panels are suitable forvarious applications, as an external cladding material in thesystems of suspended ventilated facades (SVF) forconstruction and modernization of buildings [7],[8].

Ability to be worked into a variety of shapes, the panel issuitable for increased demand for better design andarchitecture. It enables curved surfaces to be wrapped instriking colours to create a new elegance in buildings andconstructions [9].

The latest - third generation technology of mechanical &chemical bonding gives of the panels an exceptional bondintegrity. Protective coating for the panels is Durall 600®.Developed by NTC laboratories (USA) [10].

The diagram of the "Q-sun" weathering test shows thatcoating is much more stable to UV radiation than PVDF andPolyester paint [10].

Coating, which ensures perfect anticorrosion protection,excellent coating resistance to wear and environmentalinfluences. The back of the panel is protected with ananticorrosion polyester coating of 7-8 micron [7],[8].

Fig. 1 Hot rolled profiles [11]

TABLE 1MECHANICAL PROPERTIES AND CHEMICAL COMPOSITION

OF STEEL RST 37,2 DIN 17100 [11],[12]

Fig. 2 The structure of aluminium composite panels [10]:1.Protection film, 2. PE, PVDF or Durall 600 coating, 3.

Macromolecular adhesive film, 4.LDPE or mineral FR core,5. Aluminium sheet EN AW 3003 H14

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The main competitive advantage of aluminium composite,in comparison with other cladding materials is a possibility totransform a flat sheet into any nonlinear form and tomanufacture one-piece (monoblock) products of a complicatedform for easy cladding of buildings of any architecturalcomplexity [7,8].

Large sizes, low weight and aluminium composite panel’ssheets rigidity allow manufacturing cassettes of big formats,ensuring minimal installation time [7,8].

- for finishing elements – galvanized steel 1 mm,

- SSF that are used are from company HILTI [6]Ø screws 7504P 3, 9x19,Ø chemical anchors HVZ -M12x125 with HVU-TZand anchors studs HAS-TZ/HAS-R TZ.

3.2 Strength checksThe machining engineers, although have the

recommendations from the architects and structural engineersabout what profiles to use need to undergo strength checks[3]. They are attached to the exposed sections. The mainworkloads faced bay metal structures are made of wind. Foreach geographical area there are recommended values ofextreme loads, the area of the city for which it is intended tousing a design they are within Wt=0,405kN/m2 [1].

3.2.1 Check the deflection of the vertical profilesK80x80x4

In strength calculations profiles important point is theverification of the profile, i.e. the determination of thedeflection, and comparing it with the maximum deflectionpermissible in regulations. Often in practice the maximumdeflection of the profile is assumed to be yc=l/300.Calculations are performed by analysis module "Executestandard wizard" for strength checks of elements.

The scheme, the nature and dimension of the load are in afunctional depending on the type of construction. Thecommand has a set of five standard categories computingdevice solutions. They are activated by a dialog box and aredisplayed on the auxiliary display. The function has a richlibrary of standard geometric and dynamic characteristics [1] –fig. 4.

Calculation operations under pressure, bending, shear,crush and tension, use mathematical apparatus, whoseaddictions may be demonstrated at any time by the user. By

their nature these are known dependencies on classicalmechanics found application in strength theories. Afterchoosing a category is going to specify the load chart - fig. 5.

Choose a scheme with two mainstays – Two supports. Inthis case, the system offers six schemes in which calculationsare carried out – the choice is a schem 6 with duplex stationaryfastening – fig. 6.

Fig. 3 "Q-sun" diagram - Durall 600 coating [10]

Fig. 4 Five standard categories of computing circuit designsolutions

Fig. 5 Flexion simple

Fig. 6 Scheme of load

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From here on it is required to enter the value of the load,the length of the element, the moment of inertia of the profile,etc. – fig. 8.

where:- l=2749mm – length of the capital,- Pw[N] – wind load – fig.7.

kNFWP tw 033,1551,2.405,0 === (1)

-Wt = 0,405 kN/m2 – wind,-F= 2,551 m2 – area of segment.

The result is shown in fig.9. Deflection is yc = 0,642 mm.→ The selected profile К80х80х4 is appropriate,

yc=0,642<[yc]= l/300=9,16mm.

3.2.2 Choice of anchorsAnchors are chosen depending on the load shear. For this

case it is equal to the load of snow Ps = 13,22kN plusindividual weight - PI = 10,12kN, distributed for four anchorsupported the construction Pa:

kNPa 835,54

12,1022,13 =+= (2)

where:- Ps = 13,22kN It is defined as:

kNFStFs 22,1331,9.42,1. === (3)

- St=1,42 kN/m2 – load of snow,- PI = 10,12 kN - individual weight of sctructure.

Select anchors with [Pa] = 15,4kN>5,835Pa- chemicalanchors HVZ-M12x125, packaging, TZ-HVU, anchor stud-HAS-TZ/TZ-R HAS [6]

3.2.3 Strength - deformation check on FEMThe check is realized in the area of mounting consoles and

is depicted graphically in Figure 10. It is performed on datafrom previous tests that have been realized modulusrespectively wind loading My [kN.m], snow load Mz [kN.m]and force Px [kN].

( )[ ] mkNlPPM Isz .69,48

2707,8.18cos.76,11

2.cos.''

==+

=oa (4)

mkNlP

M wy .75,16

4707,8.695,7

4.

=== S (5)

from here :

kNPP Is 67,112/)12,1022,13('' =+=+ (6)

Fig. 8 Calculation parameters

Fig. 7 Computational determination scheme of distributedload

Fig. 9 Deflection

Fig. 10 Determination of modulus

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kNFWP tw 695,719.405,0. === SS (7)

kNPP Is 67,112/)12,1022,13('' =+=+ (8)kNFWP tw 695,719.405,0. === SS (9)

- FS = 19 m2 – area of the entire side wall- l = 8,707 m – length of profile K80x80x4 on area of the

entire side wall.kNPPP Isx 606,318sin.67,11sin).''( ==+= oa (10)

From the results, it is apparent that the planned size ofconsoles thickness of d=8 mm, and the material they are madeRSt37,2 realize the stresses of 1,395.104 Pa and deformation is2,62mm, eligible under strain and tension limit 3,204.107Paand 5 mm.

3.3 Montage of the elementsThe mounting consoles are established by anchoring to the

bearing elements of reinforced concentrate structure. Theywere established subsequently degradable elements of themetal construction.

The metal structure is made up of individual hot rolled andwelded profiles, as welded construction. She settled on apreviously set out in the construction of metal consoles. Itconsists of three main elements – face, intermediate farm and

back farm. The structure is fully welded. The individualbeams are manufactured in workshops, through the method ofmetal inert gas welding of CO2 with fuse electrode. Аssemblyusing arc welding with fusible electrodes. Mounting schemesof individual elements are shown in fig. 12÷15.

The mounting schemes of farms included in thecomposition of the cladding substructure are shown in Figures16-18. They are fully consistent with the architectural project.The texture of aluminium composite panels imitating wood,and fully corresponds to the character of the building as awhole. Each of the panels is formed as a separate cartridge.

The design of the structure with joints 20 mm, underwritethe thermal strains, which in aluminum composite panels arewithin 12 mm, for length of 3000 mm, at a temperature rangeof T= - 20Cº ÷ 70Cº.

Fig. 11 Strength - deformation FEM check on console

Fig. 12 Mounting plan - pergola construction 1 - face

Fig. 13 Mounting plan - pergola construction 1 – back farm

Fig. 14 Mounting plan - pergola construction 1 – side walls

Fig. 15 Metal structure – general view 3D

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In finished form the construction of pergola without andmounted on her cladding from aluminium composite panels isshown in fig.19 and fig.20.

4. RESULTSThe proposed structure, the analyzes and the results allow

to be made following conclusions:1. Proposed and testing an innovative methodology for

the design of rights, decorative, standing metalpergola, covered with aluminum composite panels,representing ending architectural solution of an officebuilding Class A (-),

2. Held analyses, combining classical computing methodsand using the finite element method, through theplatforms of TopSolid "Execute standard wizard" and"CastorXpress", demonstrate the applicability of thepreparation for construction metal profiles and bearingelements.

3. Testing in real terms methodology allows the effect tobe created parametric intelligent component modules,the use of which reduces the design process, in theimplementation of all applicable building regulationsrequired for the facilities of a this type.

5. CONCLUSIONSThe structure is designed, developed, tested and installed

as part of the facade of the administrative building Class A (-)of the company Preciz Al Ltd, Bulgaria. Development andresults are fully applied in nature. Putting architecturalelement of this type, although costs incurred increases thelevel of the site in accordance with the establishedcategorization scale, gives a modern architectural appearanceof the facade and the completion of the building exterior.

REFERENCES[1] Gere, J. M., Mechanics of Materials, Sixth Edition, Brooks/Cole, 2004.[2] Dimitrov V.,V.Dimitrova, S. Deckova, B.Mitev, Design Of A Metal Canopy

With HPL Panels, International Journal of Innovative Science, Engineering &Technology (IJISET), Vol. 3 Issue 3, March, ISSN 2348 – 7968, 2016

[3] http://expressjour.com/product[4] http://www.comfort.bg/bg/interesno/view/2734.html[5] http://www.arteks.net/[6] https://www.us.hilti.com/[7] http://chemiplast.com/sunbond_structure.htm[8] http://stab-group.com/en/products/acpanels/[9] http://www.haida.com.sg/product-panels.html[10] http://alucofront.us/overview.html[11] http://www.b2bmetal.eu/i-sections-inp-specification[12] http://www.steel-grades.com/Steel-grades/Carbon-steel/rst372.html

Fig. 17 Mounting plan - pergola sub construction 2 – sidewall

Fig. 16 Mounting plan - pergola sub construction 1 – face

Fig. 18 Pergola sub construction – general view 3D

Fig. 19 Pergola without cladding

Fig. 20 General view of construction withmounted cladding from Aluminium

composite panels

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Documents

Approach for Automated Design of Metal Pergola … CAD/CAM Software TopSolid.v.6.15 Ventsislav Dimitrov, Mariyana Ivanova, Rumen Yankov, Nikolay Nikolov Abstract— The article proposed