Efficient Cost-Based Design Optimization of Castellated Beams with Circular and Hexagonal Openings Using the Grey Wolf Algorithm

This study investigates the cost-based optimal design of castellated steel beams with circular and hexagonal web openings using the Grey Wolf Optimizer (GWO) algorithm. The research aims to minimize fabrication cost while ensuring compliance with structural performance requirements. Several design examples from existing literature are examined to evaluate the algorithm’s performance under different loading conditions and geometric configurations. The optimization process incorporates geometric parameters, strength constraints, and serviceability limits. Comparative analyses with established benchmark studies are conducted to assess the quality and consistency of the obtained solutions. The results indicate that the GWO algorithm achieves modest but meaningful improvements in cost efficiency and demonstrates stable convergence behavior across all investigated cases. These findings highlight the suitability of metaheuristic optimization techniques for structural applications and reinforce the potential of GWO as a reliable tool for developing economical and practical castellated beam designs. Future extensions may include multi-objective optimization or additional opening geometries.