Genetic-Algorithm-Based Approach for the Design Optimization of Flexible Kerf Structures

Kerfing (relief cutting) is a fabrication technique used to create flexible surfaces by cutting into a planar panel along specific cut patterns, referred to as kerf patterns. Kerf panels are formed by tessellating unit kerf cells on the surface and can facilitate load transfer and redistribute stresses through localized unit-cell deformation. This deformation can be controlled by varying kerf geometric parameters and/or material properties. This study utilizes a genetic algorithm to optimize kerf parameters for unit cells of the panel, subjected to various types of loading conditions. The objective of this optimization is to achieve as uniform a stress distribution as possible while ensuring that the peak stress and displacement remain below the specified yield and maximum displacement thresholds. Commercial finite element analysis software is used to design and simulate the beam element model of kerf panels. Several case studies of panels subjected to various loading conditions are reported to test the robustness of the algorithm. Results suggest that the optimized panels exhibit better stress distribution, as indicated by a lower coefficient of variation value (a statistical measure of uniformity) compared to those formed by manual intuition or a trial-and-error method.