Topology optimization of SPF/DB-formed corrugated sandwich structure with process constraints

IF 8.3 1区工程技术 Q1 ENGINEERING, CIVIL

Thin-Walled Structures Pub Date : 2026-05-01 Epub Date: 2026-02-19 DOI:10.1016/j.tws.2026.114696

Ming Liu, Hanbin Wang, Wenjiong Chen, Shutian Liu

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引用次数: 0

Abstract

Superplastic forming/diffusion bonding (SPF/DB) is an advanced manufacturing technology to fabricate components with complex geometries. This process enables the production of intricate mechanical structures with enhanced performance, while significantly reducing part count and assembly complexity. However, the mechanical properties of SPF/DB sandwich structures are critically dependent on the topological configuration of their core layers. This highlights the need for a topology optimization methodology specifically adapted to the SPF/DB processes, taking into account relevant manufacturing constraints. In this study, an integrated topology optimization framework for SPF/DB sandwich structures is proposed, which employs the Beluga Whale Optimization (BWO) algorithm to achieve high-performance designs under realistic fabrication limitations. The proposed approach establishes a seamless workflow that integrates modelling, simulation, and optimization, thereby offering a systematic design strategy for SPF/DB structures that rigorously incorporates fabrication limitations. The effectiveness of the method is demonstrated through two illustrative case studies. This work provides valuable guidance for the initial layout design of diffusion bonding regions in lightweight sandwich structures under SPF/DB process constraints. Moreover, it contributes to the broader application of topology optimization techniques in SPF/DB manufacturing.

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具有工艺约束的SPF/ db成型波纹夹层结构拓扑优化

超塑性成形/扩散键合（SPF/DB）是一种制造复杂几何形状部件的先进制造技术。该工艺能够生产具有增强性能的复杂机械结构，同时显着减少零件数量和装配复杂性。然而，SPF/DB夹层结构的力学性能严重依赖于其核心层的拓扑结构。考虑到相关的制造限制，这突出了对专门适用于SPF/DB工艺的拓扑优化方法的需求。在本研究中，提出了一种SPF/DB夹层结构的集成拓扑优化框架，该框架采用白鲸优化（Beluga Whale optimization， BWO）算法，在现实制造限制下实现高性能设计。所提出的方法建立了一个集成建模、仿真和优化的无缝工作流程，从而为严格结合制造限制的SPF/DB结构提供了系统的设计策略。通过两个实例验证了该方法的有效性。该工作为SPF/DB工艺约束下轻质夹层结构扩散键合区的初始布局设计提供了有价值的指导。此外，它有助于拓扑优化技术在SPF/DB制造中的广泛应用。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Thin-Walled Structures 工程技术-工程：土木

CiteScore

9.60

自引率

20.30%

发文量

801

审稿时长

66 days

期刊介绍： Thin-walled structures comprises an important and growing proportion of engineering construction with areas of application becoming increasingly diverse, ranging from aircraft, bridges, ships and oil rigs to storage vessels, industrial buildings and warehouses. Many factors, including cost and weight economy, new materials and processes and the growth of powerful methods of analysis have contributed to this growth, and led to the need for a journal which concentrates specifically on structures in which problems arise due to the thinness of the walls. This field includes cold– formed sections, plate and shell structures, reinforced plastics structures and aluminium structures, and is of importance in many branches of engineering. The primary criterion for consideration of papers in Thin–Walled Structures is that they must be concerned with thin–walled structures or the basic problems inherent in thin–walled structures. Provided this criterion is satisfied no restriction is placed on the type of construction, material or field of application. Papers on theory, experiment, design, etc., are published and it is expected that many papers will contain aspects of all three.