Mono-sized sphere packing algorithm development using optimized Monte Carlo technique

In this paper, fuel cell catalyst layer was developed using the optimized sphere packing algorithm. An optimization technique named adaptive random search technique (ARSET) was employed in this packing algorithm. The ARSET algorithm will generate the initial location of spheres and allow them to move in the random direction with the variable moving distance, randomly selected from the sampling range (α), based on the Lennard–Jones potential and Morse potential of the current and new configuration. The solid fraction values obtained from this developed algorithm are in the range of 0.610–0.624 while the actual processing time can significantly be reduced by 5.58–34% based on the number of spheres. The initial random number sampling range (α) was investigated and the appropriate α value is equal to 0.5.

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• We employed the adaptive random search technique in the sphere packing algorithm.
• The total potential energy of each packing configuration reached the global minimum state.
• Actual processing times were reduced by 5.58–34% compared to the basic random search technique.
• The appropriate initial search range (α) should be equal to 0.5.