Aerodynamic Optimization of Relay Nozzle Using a Chebyshev KAN Surrogate Model Integration and an Improved...

In air jet looms, relay nozzles are critical components in governing airflow velocity and air consumption during the weft insertion process. Although computational fluid dynamics (CFD) offers high-fidelity simulation for aerodynamic analysis, its computational burden hinders its practicality in iterative aerodynamic design of relay nozzles. To address the challenge, this study proposes a data-driven framework integrating a Chebyshev polynomial Kolmogorov-Arnold Network (Chebyshev KAN) surrogate model with an Improved Multi-objective Red-billed Blue Magpie Optimizer (IMORBMO). The accuracy of the Chebyshev KAN model was benchmarked against conventional multilayer perceptrons (MLP), convolutional neural networks (CNN), and the standard Kolmogorov-Arnold Network (KAN). Experimental results demonstrate that the Chebyshev KAN model achieves the lowest mean absolute error (MAE) of 0.103 for airflow velocity and 0.115 for air consumption. Building upon the non-dominated sorting and crowding distance strategies, IMORBMO was developed, incorporating an adaptive mutation mechanism by information entropy for improvement of convergence, diversity, and uniformity of the Pareto-optimal solutions. Comprehensive evaluations on the ZDT and WFG benchmark suites confirm that the IMORBMO consistently attains the best and highly competitive performance, yielding the lowest generation distance (GD), inverted generational distance (IGD) values and the highest hypervolume (HV). Applied to the aerodynamic optimization of a relay nozzle, the proposed framework delivers an optimal aerodynamic design that increases airflow velocity by 10.5% while reducing air consumption by 15.4%, as verified by CFD simulation. The steady-state flow field was simulated by solving the Reynolds-Average NavierStokes equations with the k-ω turbulent model, utilizing Fluent 2025.R2. No-slip wall, inlet pressure and outlet pressures are boundary conditions to the relay nozzle surfaces. This work establishes a computationally efficient and accurate optimization paradigm that holds significant promise for aerodynamic design and other complex real-world engineering applications.