Abstract

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.

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