Effect of Web Perforations on the Web Buckling Resistance of 7075-T6 and AA-6086 High-Strength Aluminium Alloy C-Shaped Members under End-Two-Flange Loading Case

Recently, new types of C-shaped members made from AA-6086 and 7075-T6 high-strength aluminium alloy have become more popular due to their high yield strength and lower cost. These members are often manufactured with pre-punched web perforations to simplify the installation of services, but this can reduce their strength. Also, such aluminium C-shaped members that contain perforated webs are vulnerable to web buckling failure, as aluminium alloy has a lower elastic modulus compared to steel. However, this influence has not been investigated for high-strength aluminium alloy sections to date. An extensive numerical investigation was undertaken to examine the effect of web perforations on the web buckling resistance of high-strength aluminium alloy C-shaped members under an end-two-flange (ETF) loading case, and this study focused on two types of aluminium alloys, namely 7075-T6 and AA-6086. To achieve this, a nonlinear finite element (FE) model was developed and validated using the test data in the literature. The material properties used in the FE models were obtained from the relevant literature. A parametric investigation was carried out, consisting of a total of 1458 models. In this investigation, a number of variables were examined, including the web hole size, web hole location, bearing length, fillet radius and aluminium alloy grades. The results showed that increasing the a/h ratio from 0.1 to 0.5 resulted in a decrease of 9.7% and 9.3% in the web buckling resistance for the 7075-T6 aluminium and AA-6086 aluminium, respectively. When the length of the bearing plates (N) varied from 100 mm to 200 mm, the web buckling resistance experienced an average increase of 61.7% for the 7075-T6 aluminium and 54.1% for the AA-6086 aluminium. Also, the web buckling resistance increased by 6.2% for the 7075-T6 aluminium alloy, while the strength increased by 4.0% for the AA-6086 aluminium alloy when the x/h ratio increased from 0.1 to 0.5. The numerical data generated from the parametric study were used to assess the accuracy and suitability of the latest design recommendations, and it was found that the design rules presented in the previous literature cannot provide reliable and safe predictions for estimating the web buckling resistance of aluminium C-shaped members that contain perforated webs under an ETF loading case. Finally, new design formulas were proposed in the form of strength reduction factors. A reliability assessment was then undertaken, and the results of this analysis indicated that the proposed design formulas can accurately predict the web buckling resistance of such members with perforated webs.

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