The design of steel connections presents considerable complexity due to their inherently nonlinear behavior, cost constraints, and the necessity to comply with structural design codes. These factors highlight the need for advanced computational algorithms to identify optimal solutions. In this study, a comprehensive computational framework is presented in which the finite element method (FEM) is integrated with a genetic algorithm (GA) to optimize material usage in bolted steel end-plate joints, while structural safety is ensured based on multiple performance criteria. By incorporating both material and geometric nonlinearities, the mechanical response of the connections is accurately captured. The proposed approach is applied to a representative beam-to-column assembly, with numerical results verified against experimental data. By employing the framework, an optimized layout is obtained, yielding a (Formula presented.) improvement in the overall performance objective compared to the best-performing validated model and a (Formula presented.) reduction in material volume relative to the most efficient feasible alternative. Furthermore, a (Formula presented.) decrease in equivalent plastic strain is achieved compared to the configuration exhibiting the highest level of inelastic deformation. These findings demonstrate that the developed method is capable of enhancing design efficiency and precision, underscoring the potential of advanced computational tools in structural engineering applications.

The equivalent T-stub method is frequently employed in infrastructure projects, including bridge engineering, to simplify bolted connection analysis. However, steel connections remain inherently complex due to nonlinear behavior, cost considerations, and code compliance, framing the design process as a discrete structural optimization problem. This research addresses these challenges by presenting a comprehensive calculation framework that combines the finite element method (FEM) and genetic algorithm (GA) to accurately evaluate the structural performance of bolted T-stub configurations. The proposed approach accounts for nonlinear behavior, thereby reflecting realistic structural responses. To enhance the simulation efficiency and reduce the computational time without significantly compromising accuracy, the study introduces a simplified modeling methodology. The effectiveness of the approach is demonstrated through the development and experimental validation of a selected T-stub connection. Furthermore, a parameter sensitivity analysis is conducted to showcase the range of possible outcomes, emphasizing the potential for optimization. Finally, the proposed connections were optimized using GA, highlighting the benefits of structural optimization in achieving efficient and precise designs for steel connections.