Intelligent design of cooling systems for aluminum alloy die-casting dies: A framework integrating topology optimization and particle swarm optimization

• The proposed MMC-PSO framework automatically generates efficient cooling channel layouts for aluminum alloy die-casting dies, improving thermal uniformity. • The optimized cooling system reduces temperature standard deviation by 30 seconds compared to conventional and no-cooling benchmarks, without compromising average temperature. • The framework includes systematic initialization, temperature-based sorting, overlap removal, and interconnection to ensure manufacturability. • The method addresses challenges in large thin-walled aluminum alloy castings, potentially reducing defects like shrinkage porosity and deformation.