Topological optimization of magnetic pulse welding coils with a connectivity-constrained particle swarm optimization algorithm

Sen Lin; Nengzhuo Chou; Yujia Zhao; Yangfan Qin; Hao Jiang; Junjia Cui; Guangyao Li; Yi Min Xie

Materials & Design (Dec 2022)

Topological optimization of magnetic pulse welding coils with a connectivity-constrained particle swarm optimization algorithm

Sen Lin,
Nengzhuo Chou,
Yujia Zhao,
Yangfan Qin,
Hao Jiang,
Junjia Cui,
Guangyao Li,
Yi Min Xie

Affiliations

Sen Lin: State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China
Nengzhuo Chou: State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China
Yujia Zhao: State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China
Yangfan Qin: State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China
Hao Jiang: State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China
Junjia Cui: State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China
Guangyao Li: Shenzhen Automotive Research Institute, Beijing Institute of Technology, Shenzhen 518118, Guangdong, China
Yi Min Xie: Centre for Innovative Structures and Materials, School of Engineering, RMIT University, GPO Box 2476, Melbourne 3001, Australia

Journal volume & issue: Vol. 224
p. 111337

Abstract

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A connectivity-constrained optimization methodology based on a discretized particle swarm optimization (PSO) algorithm is proposed for the continuum structural design of a magnetic pulse welding coil. To address the classical continuum topological challenges of conductors, such as simple connectivity and checkerboard phenomena in the optimal topology, the PSO algorithm is combined with connectivity constraints and filtration. The evolutionary history and parametric tests in an electromagnetic structure study are employed to demonstrate the efficiency and robustness of the novel algorithm. Physical tests show that the optimized coil can form a larger effective welding area between aluminum alloy (AA5052) and steel (HC420LA) sheets compared with the joint formed by the original coil. The maximum tensile load is also significantly improved by 19.88% with a discharge energy of 22 kJ.

Published in Materials & Design

ISSN: 0264-1275 (Print); 1873-4197 (Online)
Publisher: Elsevier
Country of publisher: United Kingdom
LCC subjects: Technology: Electrical engineering. Electronics. Nuclear engineering: Materials of engineering and construction. Mechanics of materials
Website: https://www.journals.elsevier.com/materials-and-design

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