Neural network-based surrogate modeling for buckling performance optimization of lightweight-composite collapsible tubular masts

: The collapsible tubular mast (CTM) can be compactly folded for transport and deployed in orbit to serve as a key structural element. Once deployed, the CTM is vulnerable to buckling under axial load and bending moments, compromising its load-bearing capacity. The intricate relationship between the CTM's cross-section and its buckling behavior poses a significant challenge for designers. This is due to the ultra-thin nature of the CTM, which gives rise to highly localized buckling modes rather than global ones. To overcome this challenge, we developed surrogate models using a neural network (NN) trained with data from finite element analysis (FEA). These NN-based surrogate models provide high computational accuracy in predicting nonlinear buckling loads under axial force and bending moments around the two principal axes of the CTM's cross-section, achieving R2 values of 0.9906, 0.9987, and 0.9628, respectively. These models also significantly improve computational efficiency, reducing prediction time to a fraction of a second compared to several minutes with FEA. Furthermore, the NN-based surrogate models enable the usage of the non-dominated sorting genetic algorithm (NSGA-II) for multi-objective optimization (MOO) of the CTMs. These models can be integrated in the NSGA-II algorithm to evaluate the objective function of existing and new individuals until a set of 1000 non-dominated solutions, i.e., cross-sectional configurations optimizing buckling performance, is identified. The proposed approach enables the design of ultra-thin CTMs with optimized stability and structural integrity by promoting design decisions based on the quantitative information provided by the NN-based surrogate models.