A method for designing a catalytic converter optimally with a genetic algorithm is provided to design an optimal shape of the catalytic converter to reduce harmful exhaustion gas of a vehicle, a chimney, or an incinerator by using the genetic algorithm based on an input condition such as various design parameters and objective functions. An objective function for obtaining an optimal design value of a catalytic converter is calculated. A non-linear value is calculated by using a design variable for attaining the objective function as an input condition. Data I/O(Input/Output) and optimization processes are controlled between previous two stages. A new design variable is generated by crossing individuals having the best suitability in each generation when an optimization model does not satisfy an optimization convergence condition. The new design variable is transferred to a first stage and the previous processes are repeated until the optimization convergence condition over a predetermined level is satisfied. The objective function minimizes discharge of carbon mono oxide discharged from the catalytic converter by reducing a light-off time of the catalytic converter. The design parameter is a cell density, a length, a radius, a wall thickness of a monolith, and a coefficient of a catalyst distribution function.
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