Finding the optimal shape of the leading-and-trailing car of a high-speed train using design-by-morphing

We present a new, general design method, called design-by-morphing for an object whose performance is determined by its shape due to hydrodynamic, aerodynamic, structural, or thermal requirements. To illustrate the method, we design a new leading-and-trailing car of a train by morphing existing, baseline leading-and-trailing cars to minimize the drag. In design-by-morphing, the morphing is done by representing the shapes with polygonal meshes and spectrally with a truncated series of spherical harmonics. The optimal design is found by computing the optimal weights of each of the baseline shapes so that the morphed shape has minimum drag. As a result of optimization, we found that with only two baseline trains that mimic current high-speed trains with low drag that the drag of the optimal train is reduced by $$8.04\%$$8.04% with respect to the baseline train with the smaller drag. When we repeat the optimization by adding a third baseline train that under-performs compared to the other baseline train, the drag of the new optimal train is reduced by $$13.46\%$$13.46%. This finding shows that bad examples of design are as useful as good examples in determining an optimal design. We show that design-by-morphing can be extended to many engineering problems in which the performance of an object depends on its shape.