Shape design sensitivity analysis of built-up structures

Selection of the best shape of a fillet in a tension bar such that no yielding occurs has long attracted the attention of engineers. Dimensions and notations for the bar and fillet are shown. With symmetry, only the upper half of the bar is considered. The optimal design problem is to find a boundary shape to minimize the total area of the fillet such that no yielding occurs. The classical boundary value problem is reduced to a variational or energy related problem which not only has excellent properties of existence and uniqueness but also provides the mathematical foundation for finite element analysis. The variational formulation may be viewed as the principle of virtual work and the finite element method as a application of the Galerkin method to the variational equation for approximate solution of the boundary value problem.