1. Introduction
Ground transport networks have steadily developed worldwide, aiming to foster economic growth and development, link regions and communities separated by geography and create new opportunities for people. Technological advances in recent decades have turned into standard engineering practice former challenges, such as building bridges with spans well above 1 km. Nowadays, the engineering challenges in the design of long-span suspension bridges are in the range above 2000 m, while, for cable-stayed bridges, the equivalent mark could be set in span lengths above 1000 m.
Due to the exceptional flexibility of such long-span structures, safety with regard to aeroelastic effects becomes the dominant design factor, at least from a wind engineering perspective. Focusing on flutter performance, the safe design of ultra-long span bridges certainly benefits from twin-box deck design. Examples of long span suspension bridges constructed adopting a twin-box arrangement are the Xihoumen Bridge in China, with a main span of 1650 m [
1], the Yi Sun-Sin Bridge in South Korea, featuring a 1545 m central span [
2], or the 1915 Çanakkale Bridge in Turkey with a main span of 2023 m, which is the longest in the [
3]. It can be noted that all of them, with main spans above 1500 m, must resort to the twin-box arrangement to meet the critical flutter speed requirements. At a fundamental level, the slot between boxes favours a higher flutter critical wind speed, as the gap between boxes is intended to decrease the slopes of lift and moment coefficients, reducing aeroelastic coupling between the torsional and vertical modes [
4] causing, in general, a decrease in the
flutter derivative [
5].
Research addressing the aeroelastic performance of twin-box cable-supported bridges has mainly focused on parametric variation studies considering a small number of design variables. In [
6], a parametric study based on the sensitivity of the flutter derivatives with respect to the gap distance was conducted for the box geometry of the Stonecutters bridge, finding a higher torsional damping ratio for larger gap widths. In a subsequent work [
7], the authors studied several configurations with different gap widths and torsion–bending frequency ratios without introducing changes in the box geometry. Another parametric study based on wind tunnel testing is reported in [
8], who studied two 20:1 side ratio rectangular cylinders in tandem arrangement, considering different gap distances along with gratings and vertical plates, demonstrating that the
flutter derivative is the one featuring a dependence on the gap length. More recently, additional design variables have been considered in parametric studies dealing with the flutter performance of cable-supported twin-box deck bridges. In [
9], two different wind fairing shapes, symmetric and asymmetric, were considered along with several gap widths to investigate torsional divergence and flutter performance. The main conclusion of this study was that “
the favorable aerodynamic effects of the center slot on bridge decks depend on the aerodynamic shape of the box girders and on the slot widths rather than unconditionally improving the aeroelastic stability”. Similarly, in [
10], the authors adopted an experimental approach to analyse the effect of several vertical central stabilizers (VCSs) for a twin-box deck considering different gap distances. However, in [
11], it is shown how minimal changes in the geometry of the deck, such as introducing a cut in the internal lower corner of the boxes facing the gap, produces a strong non-linear response affecting the aeroelastic torsional damping.
The review of the literature addressing the design of twin-box decks based on experimental testing shows the complex relationship between aeroelastic response and the deck shape, remarkably gap distance and box geometry. In addition, the large number of deck shape design variables precludes a thorough analysis based only on wind tunnel testing. As a matter of fact, in the last reference, it is stated “Considering all the possible combinations of the main geometrical parameters, many configurations should be tested to find the best solution for the project. This would lead to a very large number of experimental tests … a common industrial procedure is to quickly sift and select 2 or 3 configurations with better performances, …”. Such heuristic design procedure might provide a feasible design when relying on the previous experience of the design team; however, in the absence of a proper assessment of the full design domain under consideration, there is a true possibility for missing more efficient designs, given the complexity of the interplay between deck geometry and gap distance. This frames the target of this piece of research: improve wind tunnel-based design techniques by proposing a rigorous design framework founded upon the application of validated CFD (Computational Fluid Dynamics) simulations in the frame of surrogate-based design to explore an ample twin-box deck shape design domain, identifying the most efficient candidate designs for the ultimate detailed design of a cable-supported bridge.
A surrogate model might be considered as a “cheap-to-evaluate” function that emulates the “expensive-to-evaluate” continuous quality, cost or performance metric of a product or process. Since the evaluation of the output is so costly, only the output of a limited number of “samples” should be obtained, adopting this sparse set of samples to define an approximation that enables a cheap performance prediction [
12]. The evaluation of aerodynamic and aeroelastic responses in wind engineering applications is a complex task, with heavy burdens, associated with experimental tests or CFD simulations.
Consequently, surrogate models have been applied in a relatively limited range of wind engineering applications. In [
13], the authors defined a Kriging surrogate in the frame of the shape optimization of the cross-section geometry of high-rise buildings, considering both drag and lift coefficients. A multi-fidelity surrogate model was later presented in [
14] for the drag coefficient and the standard deviation of the lift coefficient of buildings, based on samples evaluated using RANS (Reynolds-averaged Navier–Stokes) and LES (Large Eddy Simulations) simulations. The surrogate model was applied in the context of an aerodynamic multi-objective optimization of tall buildings. In the study of vertical axis wind turbines, a Kriging model was defined, linking the power coefficient with two airfoil design variables, namely the maximum camber and its position [
15]. In [
16], the authors trained and compared six different neural network (NN) models to obtain surrogates for the aerodynamic loads on wind turbine blades. In [
17,
18], the multi-objective shape optimization of the cross-sections of tall buildings was addressed, considering a Kriging surrogate model for the aerodynamic response of the buildings, based on Eurocode stipulations.
Turning the focus now to surrogate modelling applications in the aeroelastic response of long span bridges, some of the authors of this work have been active in the surrogate-based optimal design of cable-supported bridges, co-authoring the articles [
19,
20,
21]. These optimization works relied on the ability of the surrogate model to provide the data required for the evaluation of the aeroelastic responses of interest in the numerical optimization process for the modified designs. This framework was first reported in [
22]. In this last reference, two design variables, namely the depth and the width of a box girder, were considered for the aerodynamic characterization of the deck. A set of 15 samples were defined deterministically over the design domain, and the force coefficients were obtained by means of 2D URANS (Unsteady Reynolds-averaged Navier-Stokes) simulations, validating the results of a subset of three designs using wind tunnel data. In a subsequent step, a Kriging surrogate model was defined for the force coefficients and their slopes at a 0° angle of attack, enabling the approximation of the flutter derivatives, adopting the quasi-steady theory. Finally, the surface response for the critical flutter speed over the considered design domain was obtained for two application cases. In [
23], the previous framework was extended by including an additional design variable: the gap distance between girders. In that case, the definition of the samples over the three-dimensional design domain (box width, box depth and gap distance) was carried out by applying the random Latin Hypercube Sampling (LHS) method. Afterwards, a Kriging surrogate model was trained using the aerodynamic outputs obtained for 25 samples evaluated using a 2D URANS approach. In the application case, the gap to depth ratio range considered was
G/
H = (0.51, 1.86) inside region 1, as defined in [
24]. Given the relatively short gap-width considered, the flutter derivatives were successfully approximated by the quasi-steady formulation, requiring a correction in the values of the aerodynamic centres.
The present research effort extends the research on this subject by addressing the following limitations in previous studies: (i) In addition to modifications in the width and depth of the individual boxes of the twin-box deck, large gap-widths inside region 2 [
24] were considered herein, in order to cover a more general design problem. Targeting large gaps in surrogate-based design is relevant, as experimental parametric studies have considered gap widths inside region 2, and, for instance, the Stonecutters Bridge features a gap to depth ratio of 3.7. (ii) The consideration of large slots between girders has required dropping the quasi-steady assumption for the approximation of the flutter derivatives adopted in previous research. Consequently, forced-oscillation simulations were implemented for the numerical evaluation of the flutter derivatives for the considered set of samples defining the surrogate model. In fact, this approach yields a multidimensional surrogate model for the approximation of the flutter derivatives at 0° angle of attack (AoA), which comprises the following four (4) input variables: box width, box depth and gap distance in the twin-box deck, along with reduced velocity. (iii) Furthermore, the computational burden associated with the forced-oscillation simulations at different reduced velocities for the heave and pitch degrees of freedom is substantially higher than that associated with the evaluation of the force coefficients at a given angle of attack. To the authors’ knowledge, forced-oscillation simulations have previously never been adopted in surrogate modelling training. (iv) Finally, the nonlinearity of the aeroelastic response following changes in the deck geometry of twin-box decks has been highlighted by other researchers without outlining the global patterns; therefore, a surrogate model based on the Radial Basis Function (RBF) has been developed herein in order to identify and shed some light on the general trends in the aeroelastic response.
It is important to note that twin-box decks are prone to vortex-induced vibration (VIV), which is a phenomenon highly dependent on the gap distance between girders [
24,
25,
26,
27,
28].
The remainder of the article is organized as follows: A brief review of the fundamental formulation is provided, addressing force coefficients, flutter derivatives, Navier–Stokes equations and the Radial Basis Function (RBF) formulation for the definition of the surrogate model. In the next section, the application case is introduced, and the design of experiments methodology based upon the Latin Hypercube Sampling (LHS) method is reviewed. Afterwards, the experimental campaign conducted at the aerodynamic wind tunnel of the University of A Coruña is briefly described and the CFD modelling approach adopted for obtaining the outputs of the samples is explained, focusing on the validation of the force coefficients and the flutter derivatives with wind tunnel data for a subset of the considered samples. Finally, the multidimensional surrogate models obtained for the force coefficients and the flutter derivatives over the whole design domain considered for the twin-box deck are presented and discussed. The paper finishes summarizing the main findings in the conclusions section.
4. Wind Tunnel Testing
In
Section 3.2, it was mentioned that a subset of three deck designs among the considered set of samples for the surrogate model training were selected to be tested in the wind tunnel. In this manner the CFD simulations can be validated with experimental data.
The wind tunnel campaign was conducted at the aerodynamic wind tunnel of the University of A Coruña, which is a blown-type open circuit class facility, featuring a 1 by 1 m2 test cross-section. The sectional models were manufactured at a geometric scale of 1/70, obtaining the required stiffness by placing one aluminium bar at the core of each box girder. In order to prevent end-effects, large circular end-plates were affixed to the ends of the sectional models.
The wind tunnel tests were conducted in smooth flow. For the evaluation of the force coefficients, the sectional model was connected to the force balances by means of stiff bars, measuring the aerodynamic forces. In
Figure 5, general and more detailed views of the sectional models in the test chamber are provided. The force coefficients were obtained for the fixed models at a Reynolds number, Re, of 1.2 × 10
5, after checking the insensitivity of the results for Re > 8.0 × 10
4. The experimental values in the range (−6°, 6°) are reported in Figure 7 for cases g01, g04 and g07.
For the evaluation of the flutter derivatives, the sectional model was elastically supported by springs, behaving as a three degree-of-freedom dynamical system. For the identification of the flutter derivatives, the sectional model was released out of the balance position at different flow speeds. The Iterative Least Squares method (ILS), proposed by [
35], was adopted for obtaining the experimental flutter derivatives from the model’s displacement time-histories at different reduced velocities. The experimental flutter derivatives obtained for cases g01, g04 and g07 are reported in Figures 8–10.
8. Concluding Remarks
This work extends previous research on the development of surrogate models for the aerodynamic and aeroelastic characterization of long span bridges. The fundamental challenge addressed herein has been the multidimensionality in the inputs of the surrogate model, as four input design variables were considered for the definition of the force coefficients surrogate model: the width and depth of the individual boxes, the gap distance between boxes and the angle of attack. Similarly, for the flutter derivatives surrogate model, the input variables adopted were the width and depth of the individual boxes, the gap distance between boxes and the reduced velocity.
Another challenge has been the computation of the flutter derivatives for the 15 samples considered in the definition of the surrogate by means of 2D URANS forced-oscillation simulations in the pitch and heave degrees of freedom at five different reduced velocities. This more burdensome approach was required, as the consideration of large gap distances in the twin-box deck arrangements does not allow for the application of the quasi-steady theory for the approximation of the flutter derivatives adopted in other cases by the authors. In addition to the implicit computational burden, spatial and temporal verification studies have been completed, and the numerical data have been validated with the experimental data for a subset of three geometries within the set of samples resulting from the application of the LHS method.
The surrogate model of the force coefficients enables the identification of larger sensitivity in the lift and moment coefficient with the box width and depth, while the gap-to-depth ratio plays a decisive role only in the lift coefficient.
For the flutter derivatives, the surrogate model shows a strong dependence in the values with the gap-to-depth ratio for any given reduced velocity for
,
,
and
but a minor influence for
and
. This last flutter derivative is, however, more affected by changes in the box width
C. Furthermore, it is also interesting to note how, for a given flutter derivative and gap to depth ratio
G/
Dref, the qualitative influence of the deck depth
D and box width
C is also dependent on the reduced velocity. For instance, flutter derivatives
and
show different trends with
C/
Cref and
D/
Dref, as the reduced velocity increases for a given gap distance. On the other hand, flutter derivatives such as
and
show similar patterns with
C/
Cref and
D/
Dref, independently of the reduced velocity for a given
G/
Dref ratio. The impact of the changes in the twin-box deck geometry in the flutter response has been analysed based on the stabilizing or destabilization effect, depending on the values of each individual flutter derivative, following [
38].
In addition to the qualitative and quantitative interpretation of the aerodynamic and aeroelastic parameters, the surrogate model is ready to be applied in the application of surrogate-based design optimization problems considering the flutter, buffeting and aerostatic stability, following the methodology outlined in [
2].
As surrogate modelling techniques gain maturity, further advances would improve our understanding of the aeroelastic responses of long-span bridges. In this regard, adding additional geometric input variables, such as the length and angle of a recessed lower internal corner or the fairing corner angle, would enable a more precise tailoring of the desired flutter response, although at the expense of higher dimensionality in the model and, therefore, larger computational demands. Moreover, it was mentioned in the introduction that twin-box decks are prone to vortex-induced vibration; hence, the development of a surrogate model linking the deck geometry with the VIV response would be of utmost importance for practical long-span bridge design, wherein deck geometries showing a low excitation risk should be favoured, as they also maintain enhanced flutter performance.