CHAPTER

6
Optimum Design: Numerical Solution Process and
Excel Solver
Section 6.5 Excel Solver for Unconstrained Optimization Problems
6.1_________________________________________________________________________________
Solve the following problem using Excel Solver (choose any reasonable starting point):

Exercise 4.32

The annual operating cost U for an electrical line system is given by the following expression

(21.9𝐸𝐸 + 07)
𝑈𝑈 = + (3.9𝐸𝐸 + 06)𝐶𝐶 + (1.0𝐸𝐸 + 03)𝑉𝑉
𝑉𝑉 2 𝐶𝐶

where V=line voltage in kilovolts and C=line conductance in ohms. Find stationary points for the

function, and determine V and C to minimize the operating cost.

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
Variables V and C have been renamed V_line and C_line respectively. The objective
function and variables are input into the Solver Parameters dialog box as shown. In the
options dialog box, conjugate gradient method and forward finite difference were
selected. However, Newton method and/or central difference could have been selected
instead. Once the problem is defined, click “Solve” to solve the problem and to bring up
the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of V_line=200 and C_line=0.01, a
solution of V_line=241.8 and C_line=0.0310, which gives an objective function value of -
483,528.61, is obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.2________________________________________________________________________________
Solve the following problem using Excel Solver (choose any reasonable starting point):

Exercise 4.39

𝑓𝑓(𝑥𝑥1 , 𝑥𝑥2 ) = 8𝑥𝑥12 + 8𝑥𝑥22 − 80�𝑥𝑥12 + 𝑥𝑥22 − 20𝑥𝑥2 + 100 − 80�𝑥𝑥12 + 𝑥𝑥22 + 20𝑥𝑥2 + 100 − 5𝑥𝑥1 − 5𝑥𝑥2

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
Variables x1 and x2 have been renamed x and y respectively. The objective function and
variables are input into the Solver Parameters dialog box as shown. In the options dialog
box, conjugate gradient method and forward finite difference were selected. However,
Newton method and/or central difference could have been selected instead. Once the
problem is defined, click “Solve” to solve the problem and to bring up the Solver Results
dialog box.
(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.
(3) The answer report shows that for initial design variable values of x=4 and y=6, a solution of
x=4.15 and y=0.362, which gives an objective function value of -1616.2, is obtained.

2
1

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.3_________________________________________________________________________________
Solve the following problem using Excel Solver (choose any reasonable starting point):

Exercise 4.40

𝑓𝑓(𝑥𝑥1 , 𝑥𝑥2 ) = 9𝑥𝑥12 + 9𝑥𝑥22 − 100�𝑥𝑥12 + 𝑥𝑥22 − 20𝑥𝑥2 + 100 − 64�𝑥𝑥12 + 𝑥𝑥22 + 16𝑥𝑥2 + 64 − 5𝑥𝑥1 − 41𝑥𝑥2

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
Variables x1 and x2 have been renamed x and y respectively. The objective function and
variables are input into the Solver Parameters dialog box as shown. In the options dialog
box, conjugate gradient method and forward finite difference were selected. However,
Newton method and/or central difference could have been selected instead. Once the
problem is defined, click “Solve” to solve the problem and to bring up the Solver Results
dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x=5 and y=2, a solution of
x=3.73 and y=0.341, which gives an objective function value of -1526.6, is obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.4 _________________________________________________________________________________
Solve the following problem using Excel Solver (choose any reasonable starting point):

Exercise 4.41

𝑓𝑓(𝑥𝑥1 , 𝑥𝑥2 ) = 100(𝑥𝑥2 − 𝑥𝑥12 )2 + (1 − 𝑥𝑥1 )2

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
Variables x1 and x2 have been renamed x and y respectively. The objective function and
variables are input into the Solver Parameters dialog box as shown. In the options dialog
box, conjugate gradient method and forward finite difference were selected. However,
Newton method and/or central difference could have been selected instead. Once the
problem is defined, click “Solve” to solve the problem and to bring up the Solver Results
dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x=5 and y=2, a solution of
x=1.216 and y=1.462, which gives an objective function value of 0.0752, is obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.5 _________________________________________________________________________________
Solve the following problem using Excel Solver (choose any reasonable starting point):

Exercise 4.42

𝑓𝑓(𝑥𝑥1 , 𝑥𝑥2 , 𝑥𝑥3 , 𝑥𝑥4 ) = (𝑥𝑥1 − 10𝑥𝑥2 )2 + 5(𝑥𝑥3 − 𝑥𝑥4 )2 + (𝑥𝑥2 − 2𝑥𝑥3 )4 + 10(𝑥𝑥1 − 𝑥𝑥4 )4

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
Variables x1, x2, x3, and x4 have been renamed x, y, z, and v respectively. The objective
function and variables are input into the Solver Parameters dialog box as shown. In the
options dialog box, conjugate gradient method and forward finite difference were
selected. However, Newton method and/or central difference could have been selected
instead. Once the problem is defined, click “Solve” to solve the problem and to bring up
the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x=1, y=2, z=3, and v=4, a
solution of x=0.246, y=0.0257, z=0.1808, and v=0.205which gives an objective function value of
0.01578, is obtained.
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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

Section 6.6 Excel Solver for Linear Programming Problems

Solve the following LP problems using Excel Solver:
6.6 _________________________________________________________________________________
Solve the following LP problem using the Excel Solver:

Maximize z = x 1 + 2x 2
subject to −x 1 + 3x 2 ≤ 10
x1 + x2 ≤ 6
x1 − x2 ≤ 2
x 1 + 3x 2 ≥ 6
x1, x2 ≥ 0

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.
(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.
(3) The answer report shows that for initial design variable values of x1=0 and x2=0, a solution of
x1=2 and x2=4, which gives an objective function value of 10, is obtained.
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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.7 _________________________________________________________________________________
Solve the following LP problem using the Excel Solver:

Maximize z = x 1 + 4x 2
subject to x 1 + 2x 2 ≤ 5
x1 + x2 = 4
x1 − x2 ≥ 3
x1, x2 ≥ 0

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x1=0 and x2=0, a solution of
x1=3.67 and x2=0.667, which gives an objective function value of 6.33, is obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.8 _________________________________________________________________________________
Solve the following LP problem using the Excel Solver:

Minimize f = 5x 1 + 4x 2 − x 3
subject to x 1 + 2x 2 − x 3 ≥ 1
2x 1 + x 2 + x 3 ≥ 4
x 1 , x 2 ≥ 0; x 3 is unrestricted in sign

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x1=0, x2=0, and x3=0, a
solution of x1=0, x2=1.67, and x3=2.33, which gives an objective function value of 4.33, is
obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.9 _________________________________________________________________________________
Solve the following LP problem using the Excel Solver:

Maximize z = 2x 1 + 5x 2 − 4.5x 3 + 1.5x 4

subject to 5x 1 + 3x 2 + 1.5x 3 ≤ 8
1.8x 1 − 6x 2 + 4x 3 + x 4 ≥ 3
−3.6x 1 + 8.2x 2 + 7.5x 3 + 5x 4 = 15
x i ≥ 0; i = 1 to 4

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x1=0, x2=0, x3=0, and x4=0, a
solution of x1=1.34, x2=0.441, x3=0, and x4=3.24, which gives an objective function value of
9.73, is obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.10 ________________________________________________________________________________
Solve the following LP problem using the Excel Solver:

Minimize f = 8x − 3x 2 + 15x 3
subject to 5x 1 − 1.8x 2 − 3.6x 3 ≥ 2
3x 1 + 6x 2 + 8.2x 3 ≥ 5
1.5x 1 − 4x 2 + 7.5x 3 ≥ −4.5
−x 2 + 5x 3 ≥ 1.5
x 1 , x 2 ≥ 0; x 3 is unrestricted in sign

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x1=0, x2=0, and x3=0, a
solution of x1=0.654, x2=0.0756, and x3=0.315, which gives an objective function value of 9.73,
is obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.11 ________________________________________________________________________________
Solve the following LP problem using the Excel Solver:

Maximize z = 10x 1 + 6x 2
subject to 2x 1 + 3x 2 ≤ 90
4x 1 + 2x 2 ≤ 80
x 2 ≥ 15
5x 1 + x 2 = 25
x1, x2 ≥ 0

Solution

(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of x1=0, and x2=0, a solution of
x1=0, and x2=25, which gives an objective function value of 150, is obtained.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

Section 6.7 Excel Solver for Nonlinear Programming

Solve the following problems using Excel Solver:
6.12 ________________________________________________________________________________
Solve the following NLP problem using the Excel Solver:

Exercise 3.35 (Exercise 3.34 using inner and outer diameter as design variables)
Design a hollow torsion rod shown in Fig.E3.34 to satisfy the following requirements (created by
J.M. Trummel):

1. The calculated shear stress,𝜏𝜏 , shall not exceed the allowable shear stress 𝜏𝜏𝑎𝑎 under the normal
operation torque T o (N·m).
2. The calculated angle of twist, 𝜃𝜃, shall not exceed the allowable twist, 𝜃𝜃𝑎𝑎 (radians).
3. The member shall not buckle under a short duration torque of T max (N·m).
Requirements for the rod and material properties are given in Table E3.34(A) and E3.34(B) (select a
material for one rod). Use the following design variables:
x 1 = outside diameter of the shaft; x 2 = ratio of inside/outside diameter, d i /d o.
Using graphical optimization, determine the inside and outside diameters for a minimum mass
rod to meet the above design requirements. Compare the hollow rod with an equivalent solid
rod (d i /d o = 0). Use consistent set of units (e.g. Newtons and millimeters) and let the minimum and
maximum values for design variables be given as

𝑑𝑑𝑖𝑖
0.02 ≤ 𝑑𝑑𝑜𝑜 ≤ 0.5 m, 0.60 ≤ ≤ 0.999
𝑑𝑑𝑜𝑜

Useful expressions for the rod are:

Mass of rod: 𝜋𝜋
𝑀𝑀 = 𝜌𝜌𝜌𝜌(𝑑𝑑𝑜𝑜2 − 𝑑𝑑𝑖𝑖2 ), 𝑘𝑘𝑘𝑘
4
Calculated shear stress: 𝑐𝑐
𝜏𝜏 = 𝑇𝑇𝑜𝑜 , 𝑃𝑃𝑃𝑃
𝐽𝐽
Calculated angle of twist: 𝑙𝑙
𝜃𝜃 = 𝑇𝑇𝑜𝑜 , 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟
𝐺𝐺𝐺𝐺
Critical buckling torque: 𝜋𝜋𝑑𝑑𝑜𝑜3 𝐸𝐸 𝑑𝑑𝑖𝑖
𝑇𝑇𝑐𝑐𝑐𝑐 = (1 − )2.5 , N. m
12√2(1 − 𝜈𝜈 2 )0.75 𝑑𝑑𝑜𝑜

Notation
M = mass of the rod (kg),
𝑑𝑑𝑜𝑜 = outside diameter of the rod (m),
𝑑𝑑𝑖𝑖 = inside diameter of the rod (m),
𝜌𝜌 = mass density of material (kg/m3),
l = length of the rod (m),
T 0 = Normal operation torque (N ⋅ m),
c = Distance from rod axis to extreme fiber (m),
J = Polar moment of inertia (m4),
θ = Angle of twist (radians),
G = Modulus of rigidity (Pa),

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

T cr = Critical buckling torque (N ⋅ m),

E = Modulus of elasticity (Pa), and
𝜈𝜈 = Poisson’s ratio.

FIGURE E3-34 Hollow torsion rod.

TABLE E3-34(A) Rod Requirements

Torsion Length, Normal torque, Max. torque, Allowable twist,
rod l (m) T 0 (kN ⋅ m) T max (kN ⋅ m) 𝜃𝜃𝑎𝑎 (degrees)
number
1 0.50 10.0 20.0 2
2 0.75 15.0 25.0 2
3 1.00 20.0 30.0 2

TABLE E3-34(B) Materials and Properties for the Torsion Rod

Material Density, Allowable Elastic Shear Poisson’s
𝜌𝜌 Shear modulus, modulus, ratio (𝜈𝜈)
3
(kg/m ), stress, E (GPa) G (GPa)
𝜏𝜏𝑎𝑎 (MPa)

1. 4140 7850 275 210 80 0.30

alloy steel
2. 2750 165 75 28 0.32
Aluminum
alloy 24 ST4
3. 1800 90 45 16 0.35
Magnesium
alloy A261
4. Berylium 1850 110 300 147 0.02
5. Titanium 4500 165 110 42 0.30

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of do=400 and di=40 a solution of
do=103.0 and di=98.3 which gives an objective function value of 2.90, is obtained.

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6.13 ________________________________________________________________________________
Solve the following NLP problem using the Excel Solver:

Exercise 3.50

A minimum mass structure (area of member 1 is the same as member 3) three-bar truss is to be
designed to support a load P as shown in Fig. 2.9. The following notation may be used: P u =P cos𝜃𝜃,
P v =P sin𝜃𝜃, A 1 = cross-sectional area of members 1 and 3, A 2 = cross-sectional area of member 2.
The members must not fail under the stress, and deflection at node 4 must not exceed 2cm in
either direction. Use Newtons and millimeters as units. The data is given as P = 50 kN; 𝜃𝜃 = 30°;
mass density, 𝜌𝜌 = 7850 kg/m3; modulus of elasticity, E = 210 GPa; allowable stress, 𝜎𝜎𝑎𝑎 = 150 MPa.
The design variables must also satisfy the constraints 50 ≤A i ≤5000 mm2 .

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of A_1=250 and A_2=100 a
solution of A_1=294 and A_2=65.8 which gives an objective function value of 7.04, is obtained.

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Continued.

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6.14 ________________________________________________________________________________
Solve the following NLP problem using the Excel Solver:

Exercise 3.51

Design of a water tower support column. As a member of the ABC consulting Engineers you have
been asked to design a cantilever cylindrical support column of minimum mass for a new water tank.
The tank itself has already been designed in the tear-drop shape shown in Fig. E3.51. The height of
the base of the tank (H), the diameter of the tank (D), and wind pressure on the tank (w) are given as
H = 30 m, D = 10 m, and w = 700 N/m2. Formulate the design optimization problem and solve it
graphically. (created by G.Baenziger).
In addition to designing for combined axial and bending stresses and buckling, several
limitations have been placed on the design. The support column must have an inside diameter of at
least 0.70 m (d i ) to allow for piping and ladder access to the interior of the tank. To prevent local
buckling of the column walls the diameter/thickness ratio (d 0 /t) shall not be greater than 92. The
large mass of water and steel makes deflections critical as they add to the bending moment. The
deflection effects as well as an assumed construction eccentricity (e) of 10 cm must be accounted for
in the design process. Deflection at C.G. of the tank should not be greater than ∆ .
Limits on the inner radius and wall thickness are 0.35 ≤ R ≤2.0 m and 1.0 ≤ t ≤ 20 cm.

Pertinent constraints and formulas

h = 10 m
Height of water tank,
Allowable deflection, ∆ = 20 cm
Unit weight of water, 𝛾𝛾𝑤𝑤 = 10 kN/m3
Unit weight of steel, 𝛾𝛾𝑠𝑠 = 80 kN/m3
Modulus of elasticity, E = 210 GPa
Moment of inertia of the column, 𝜋𝜋 4
𝐼𝐼 = [𝑑𝑑 − (𝑑𝑑𝑜𝑜 − 2𝑡𝑡)4 ]
64 𝑜𝑜

Cross-sectional area of column material, 𝐴𝐴 = 𝜋𝜋𝜋𝜋(𝑑𝑑𝑜𝑜 − 𝑡𝑡)

Allowable bending stress, 𝜎𝜎𝑏𝑏 = 165 MPa
Allowable axial stress, 12𝜋𝜋 2 𝐸𝐸
𝜎𝜎𝑎𝑎 = 92(𝐻𝐻⁄𝑟𝑟 )2 (calculated using the critical
23
buckling load with factor of safety of 12
Radius of gyration,
𝐼𝐼
𝑟𝑟 = �
𝐴𝐴
Average thickness of tank wall, t t = 1.5 cm
Volume of tank, 𝑉𝑉 = 1.2𝜋𝜋𝐷𝐷2 ℎ
Surface area of tank, 𝐴𝐴𝑠𝑠 = 1.25𝜋𝜋𝐷𝐷2
Projected area of tank, for wind loading, 2𝐷𝐷ℎ
𝐴𝐴𝑝𝑝 =
3
Load on the column due to weight of water 𝑃𝑃 = 𝑉𝑉𝛾𝛾𝑤𝑤 + 𝐴𝐴𝑠𝑠 𝑡𝑡𝑡𝑡 𝛾𝛾𝑠𝑠
and steel tank,

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Lateral load at the tank C.G due to wind 𝑊𝑊 = 𝑤𝑤𝑤𝑤𝑝𝑝

pressure,
Deflection at C.G. of tank, 𝛿𝛿 = 𝛿𝛿1 + 𝛿𝛿2 ,where
𝑊𝑊𝐻𝐻 2
𝛿𝛿1 = (4𝐻𝐻 + 3ℎ)
12𝐸𝐸𝐸𝐸
𝐻𝐻
𝛿𝛿2 = (0.5𝑊𝑊ℎ + 𝑃𝑃𝑃𝑃)(𝐻𝐻 + ℎ)
2𝐸𝐸𝐸𝐸

Moment at base, 𝑀𝑀 = 𝑊𝑊(𝐻𝐻 + 0.5ℎ) + (𝛿𝛿 + 𝑒𝑒)𝑃𝑃

Bending stress, 𝑀𝑀
𝑓𝑓𝑏𝑏 = 𝑑𝑑𝑜𝑜
2𝐼𝐼
Axial stress, 𝑉𝑉𝛾𝛾𝑤𝑤 + 𝐴𝐴𝑠𝑠 𝑡𝑡𝑡𝑡 𝛾𝛾𝑠𝑠
𝑓𝑓𝑎𝑎 = �𝑃𝑃�𝐴𝐴� =
𝜋𝜋𝜋𝜋(𝑑𝑑𝑜𝑜 − t)
Combined stress constraint, 𝑓𝑓𝑎𝑎 𝑓𝑓𝑏𝑏
+ ≤1
𝜎𝜎𝑎𝑎 𝜎𝜎𝑏𝑏
Gravitational acceleration, g = 9.81 m/s2

FIGURE E3.51 Water Tower support column.

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of t=10 and R_=100 a solution of
t=2.84 and R_=129.0 which gives an objective function value of 562, is obtained.

Arora, Introduction to Optimum Design, 4e 6-19

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.14 ________________________________________________________________________________
Continued.

Arora, Introduction to Optimum Design, 4e 6-20

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.15 ________________________________________________________________________________
Solve the following NLP problem using the Excel Solver:

Exercise 3.54

Design of a tripod. Design a minimum mass tripod of height H to support a vertical load W = 60
kN. The tripod bas is an equilateral triangle with sides B = 1200 mm. The struts have a solid circular
cross section of diameter D (Fig. E3.54).
The axial stress in the struts must not exceed the allowable stress in compression, and axial load
in the strut P must not exceed the critical buckling load P cr divided by a safety factor FS = 2. Use
consistent units of Newtons and centimeters. The minimum and maximum values for design
variables are 0.5≤ H ≤5m and 0.5 ≤ D ≤50 cm. Material properties and other relationship are given
below:

Material: aluminum alloy 2014-T6

Allowable compressive stress, 𝜎𝜎𝑎𝑎 = 150MPa
Young’s modulus, E = 75 GPa
Mass density, 𝜌𝜌 = 2800 kg/m3
Strut length, 1
𝑙𝑙 = (𝐻𝐻 2 + 𝐵𝐵 2 )0.5
3
Critical buckling load, 𝜋𝜋 2 𝐸𝐸𝐸𝐸
𝑃𝑃𝑐𝑐𝑐𝑐 = 2
𝑙𝑙
Moment of inertia, 𝜋𝜋 4
𝐼𝐼 = 𝐷𝐷
64
Strut load, 𝑊𝑊𝑊𝑊
𝑃𝑃 =
3𝐻𝐻

FIGURE E3.54 A tripod.

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of H=100 and D=20 a solution of
H=50 and D=3.42 which gives an objective function value of 6.61, is obtained.

Arora, Introduction to Optimum Design, 4e 6-22

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.16 ________________________________________________________________________________
Solve the following NLP problem using the Excel Solver:

Solve the spring design problem for the following data: Applied load (P) = 20 lb.

TABLE 2.2 Information to design a coil spring

Notation Data
Deflection along spring axis δ, in
Mean Coil Diameter D, in
Wire Diameter d, in
Number of active coils N
Gravitational constant g = 386 in/s2
Frequency of surge waves ω, Hz
Weight Density of spring material γ = 0.285 lb/in3
Shear Modulus G = (1.15*107) lb/in2
Mass density of material (ρ = γ/g) ρ = (7.38342*10-4) lb-s2/in4
Allowable shear stress τ a = 80,000 lb/in2
Number of inactive coils Q=2
Applied load P = 20 lb
Minimum spring deflection Δ = 0.5 in
Lower limit on surge wave frequency ω o = 100 Hz
Limit on outer diameter of coil D o = 1.5 in

Load deflection equation: P = Kδ

d 4G
Spring Constant: K=
8D3 N

8kPD
Shear Stress: τ=
π d3

(4 D − d ) 0.615d
Wahl stress concentration factor: k= +
4( D − d ) D

d G
Frequency of surge waves: ϖ =
2π ND 2 2ρ
Design variables for the problem are defined as below:

d = wire diameter, in
D = mean coil diameter, in
N = number of active coils, integer

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

The problem to minimize the mass of the spring, given as volume*mass density is:
πd2 π d 2 (N + Q)π D ρ
Mass = ( )[(N + Q)π D]ρ =
4 4
The constraints for the spring design problem are formulated as
P
≥ ∆ , τ ≤ τ a , ω ≥ ω0 , D + d ≤ D0 , d min ≤ d ≤ d max , Dmin ≤ D ≤ Dmax , N min ≤ N ≤ N max
K

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of d=0.2, D_coil=1.3, and N=2 a
solution of d=0.0705, D_coil=0.444, and N=10.16 which gives an objective function value of
0.0268, is obtained.

3
2

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.17 ________________________________________________________________________________
Solve the following NLP problem using the Excel Solver:

Solve the spring design problem for the following data: Number of active coils (N) = 20, limit on
outer diameter of the coil (D 0 ) = 1 in, number of inactive coils (Q) = 4.
TABLE 2.2 Information to design a coil spring
Notation Data
Deflection along spring axis δ, in
Mean Coil Diameter D, in
Wire Diameter d, in
Number of active coils N
Gravitational constant g = 386 in/s2
Frequency of surge waves ω, Hz
Weight Density of spring material γ = 0.285 lb/in3
Shear Modulus G = (1.15*107) lb/in2
Mass density of material (ρ = γ/g) ρ = (7.38342*10-4) lb-s2/in4
Allowable shear stress τ a = 80,000 lb/in2
Number of inactive coils Q=4
Applied load P = 20 lb
Minimum spring deflection Δ = 0.5 in
Lower limit on surge wave frequency ω o = 100 Hz
Limit on outer diameter of coil D o = 1 in

Load deflection equation: P = Kδ

d 4G
Spring Constant: K=
8D3 N

8kPD
Shear Stress: τ=
π d3

(4 D − d ) 0.615d
Wahl stress concentration factor: k= +
4( D − d ) D

d G
Frequency of surge waves: ϖ =
2π ND 2 ρ
2

Design variables for the problem are defined as below:

d = wire diameter, in
D = mean coil diameter, in
N = number of active coils, integer

Arora, Introduction to Optimum Design, 4e 6-25

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

The problem to minimize the mass of the spring, given as volume*mass density is:
πd2 π d 2 (N + Q)π D ρ
Mass = ( )[(N + Q)π D]ρ =
4 4
The constraints for the spring design problem are formulated as
P
≥ ∆ , τ ≤ τ a , ω ≥ ω0 , D + d ≤ D0 , d min ≤ d ≤ d max , Dmin ≤ D ≤ Dmax , N min ≤ N ≤ N max
K

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of d=0.2 and D_coil=1.3 a
solution of d=0.05 and D_coil=0.282 which gives an objective function value of 0.0155, is
obtained.

3
2

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.18 ________________________________________________________________________________
Solve the following NLP problem using the Excel Solver:

Solve the spring design problem for the following data: Aluminum coil with shear modulus (G) =
4,000,000 psi, mass density (ρ) = 2.58920x10-4 lb-s2/in4, and allowable shear stress (τ a ) = 50,000
lb/in2.
TABLE 2.2 Information to design a coil spring
Notation Data
Deflection along spring axis δ, in
Mean Coil Diameter D, in
Wire Diameter d, in
Number of active coils N
Gravitational constant g = 386 in/s2
Frequency of surge waves ω, Hz
Weight Density of spring material γ = 0.285 lb/in3
Shear Modulus G = (4*106) lb/in2
Mass density of material (ρ = γ/g) ρ = 2.58920x10-4 lb-s2/in4
Allowable shear stress τ a = 50,000 lb/in2
Number of inactive coils Q=2
Applied load P = 20 lb
Minimum spring deflection Δ = 0.5 in
Lower limit on surge wave frequency ω o = 100 Hz
Limit on outer diameter of coil D o = 1.5 in

Load deflection equation: P = Kδ

d 4G
Spring Constant: K=
8D3 N

8kPD
Shear Stress: τ=
π d3

(4 D − d ) 0.615d
Wahl stress concentration factor: k= +
4( D − d ) D

d G
Frequency of surge waves: ϖ =
2π ND 2 2ρ
Design variables for the problem are defined as below:

d = wire diameter, in
D = mean coil diameter, in

Arora, Introduction to Optimum Design, 4e 6-27

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

N = number of active coils, integer

The problem function to minimize the mass of the spring, given as volume*mass density is:
πd2 π d 2 (N + Q)π D ρ
Mass = ( )[(N + Q)π D]ρ =
4 4
The constraints for the spring design problem are formulated as
P
≥ ∆ , τ ≤ τ a , ω ≥ ω0 , D + d ≤ D0 , d min ≤ d ≤ d max , Dmin ≤ D ≤ Dmax , N min ≤ N ≤ N max
K

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of d=0.2, D_coil=1.3, and N=2 a
solution of d=0.0601, D_coil=0.334, and N=8.74 which gives an objective function value of
0.0130, is obtained.

2 3

Arora, Introduction to Optimum Design, 4e 6-28

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

Section 6.8 Optimum Design of Plate Girders Using Excel Solver

Solve the following problems using Excel Solver:
6.19 ________________________________________________________________________________
Solve the following problem using the Excel Solver:

Solve the plate girder design problem for the following data: Span length (L) = 35 ft.
TABLE E6-19
Notation Data
L span, 25 m
E modulus of elasticity, 210 GPa
σy yield stress, 262 MPa
σa allowable bending stress, 0.55 σ y = 144.1 MPa
τa allowable shear stress, 0.33 σ y = 86.46 MPa
σt allowable fatigue stress 255 MPa
Da allowable deflection, L/800, m
Pm concentrated load for momemt, 104 kN
Ps concentrated load for shear, 155 kN
LLIF live load impact factor, 1+50/(L+125)
Cross-sectional area: = A (htw + 2bt f )
tw h3 2bt f bt f h(h + 2t f )
3

Moment of inertia: I= + +
12 3 2
Uniform load for the girder: =
w (19 + 77 A)
L(2 Pm + wL)
Bending moment: M =
8
M (0.5h + t f )
Bending Stress: σ=
1000 I
t
Flange buckling stress limit: σ f = 72,845[ w ]2
b
t
Web crippling stress limit: σ w = 3, 648, 276[ w ]2
h
Shear force: = S 0.5( Ps + wL)
L3 (8 Pm + 5wL)
Deflection: D=
384 *106 ( EI )
S
Average shear stress: τ=
1000htw
Objective function to minimize the material volume of the girder is defined as:
= AL
Vol = (htw + 2bt f ) L
Design variables for the plate girder optimization problem are defined as:
h = web height, m
b = flange weight, m

Arora, Introduction to Optimum Design, 4e 6-29

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

t f = flange thickness, m
t w = web thickness, m

The constraints for the spring design problem are formulated as

σt
σ ≤ σ a , σ ≤ σ f , σ ≤ σ w , τ ≤ τ a , D ≤ Da , σ ≤ ,
2
0.3 ≤ h ≤ 2.5 , 0.3 ≤ b ≤ 2.5 , 0.01 ≤ t f ≤ 0.1 , 0.01 ≤ tw ≤ 0.1
Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of h=1, b=1, tf=0.1, and tw=0.1 a
solution of h=2.5, b=0.3, tf=0.045, and tw=0.013, which gives an objective function value of
2.067, is obtained.

2
3

Arora, Introduction to Optimum Design, 4e 6-30

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.20 ________________________________________________________________________________
Solve the following problem using the Excel Solver:

Solve the plate girder design problem for the following data: A36 steel with modulus of elasticity (E)
= 200 GPa, yield stress (sigma_y) = 250 MPa, allowable fatigue stress (sigma_t) = 243 Mpa.
TABLE E6-20
Notation Data
L span, 25 m
E modulus of elasticity, 200 GPa
σy yield stress, 250 MPa
σa allowable bending stress, 0.55 σ y = 144.1 MPa
τa allowable shear stress, 0.33 σ y = 86.46 MPa
σt allowable fatigue stress 243 MPa
Da allowable deflection, L/800, m
Pm concentrated load for momemt, 104 kN
Ps concentrated load for shear, 155 kN
LLIF live load impact factor, 1+50/(L+125)
Cross-sectional area: = A (htw + 2bt f )
tw h3 2bt f bt f h(h + 2t f )
3

Moment of inertia: I= + +
12 3 2
Uniform load for the girder: =
w (19 + 77 A)
L(2 Pm + wL)
Bending moment: M =
8
M (0.5h + t f )
Bending Stress: σ=
1000 I
t
Flange buckling stress limit: σ f = 72,845[ w ]2
b
t
Web crippling stress limit: σ w = 3, 648, 276[ w ]2
h
Shear force: = S 0.5( Ps + wL)
L3 (8 Pm + 5wL)
Deflection: D=
384 *106 ( EI )
S
Average shear stress: τ=
1000htw
Objective function to minimize the material volume of the girder is defined as:
= AL
Vol = (htw + 2bt f ) L

Design variables for the plate girder optimization problem are defined as:
h = web height, m
b = flange weight, m

Arora, Introduction to Optimum Design, 4e 6-31

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

t f = flange thickness, m
t w = web thickness, m

The constraints for the spring design problem are formulated as

σt
σ ≤ σ a , σ ≤ σ f , σ ≤ σ w , τ ≤ τ a , D ≤ Da , σ ≤ ,
2
0.3 ≤ h ≤ 2.5 , 0.3 ≤ b ≤ 2.5 , 0.01 ≤ t f ≤ 0.1 , 0.01 ≤ tw ≤ 0.1
Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of h=1, b=1, tf=0.1, and tw=0.1 a
solution of h=2.11, b=0.403, tf=0.0156, and tw=0.0115, which gives an objective function value
of 0.921, is obtained.

2 3

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 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

6.21 ________________________________________________________________________________
Solve the following problem using the Excel Solver:

Solve the plate girder design problem for the following data: Web height (h) = 1.5 m, flange
thickness (tf) = 0.015 m.
TABLE E6-21
Notation Data
L span, 25 m
E modulus of elasticity, 200 GPa
σy yield stress, 250 MPa
σa allowable bending stress, 0.55 σ y = 144.1 MPa
τa allowable shear stress, 0.33 σ y = 86.46 MPa
σt allowable fatigue stress 243 MPa
Da allowable deflection, L/800, m
Pm concentrated load for momemt, 104 kN
Ps concentrated load for shear, 155 kN
LLIF live load impact factor, 1+50/(L+125)
Cross-sectional area: = A (htw + 2bt f )
tw h3 2bt f bt f h(h + 2t f )
3

Moment of inertia: I= + +
12 3 2
Uniform load for the girder: =
w (19 + 77 A)
L(2 Pm + wL)
Bending moment: M =
8
M (0.5h + t f )
Bending Stress: σ=
1000 I
t
Flange buckling stress limit: σ f = 72,845[ w ]2
b
t
Web crippling stress limit: σ w = 3, 648, 276[ w ]2
h
Shear force: =S 0.5( Ps + wL)
L3 (8 Pm + 5wL)
Deflection: D=
384 *106 ( EI )
S
Average shear stress: τ=
1000htw
Objective function to minimize the material volume of the girder is defined as:
= AL
Vol = (htw + 2bt f ) L

Design variables for the plate girder optimization problem are defined as:
h = web height, m
b = flange weight, m
t f = flange thickness, m

Arora, Introduction to Optimum Design, 4e 6-33

 Chapter 6 Optimum Design: Numerical Solution Process and Excel Solver

t w = web thickness, m

The constraints for the spring design problem are formulated as

σ
σ ≤ σ a , σ ≤ σ f , σ ≤ σ w , τ ≤ τ a , D ≤ Da , σ ≤ t ,
2
0.3 ≤ h ≤ 2.5 , 0.3 ≤ b ≤ 2.5 , 0.01 ≤ t f ≤ 0.1 , 0.01 ≤ tw ≤ 0.1

Solution
(1) One possible format for setting up the Excel worksheet for this problem is shown below.
The objective function, variables, and constraints are input into the Solver Parameters
dialog box as shown. Once the problem is defined, click “Solve” to solve the problem
and to bring up the Solver Results dialog box.

(2) Choose “Keep Solver Solution” in the Solver Results dialog box, highlight “Answers,
Sensitivity, and Limits” under Reports, and click “OK” to obtain the solution.

(3) The answer report shows that for initial design variable values of b=1 and tw=0.1 a solution of
b=0.4503 and tw=0.0675, which gives an objective function value of 2.87, is obtained.

2 3

Arora, Introduction to Optimum Design, 4e 6-34