Optimization of Cast Components for weight-effective structures

Purpose and goal

The project aimed to develop a generic methodology to enable cast lightweight components by using process simulation in parallel with topology optimization. The project results showed excellent goal fulfillment. The methodology, supported by a tailored industry course and guide lines, was demonstrated within the project for both physical and virtual components. The demonstrators showed a weight reduction between 23 and 50%. Reduced development time will be accomplished by reduced iterations between component owners and manufacturers.

Expected results and effects

The project clearly showed the need for taking the manufacturing process into account already in the early design stages. The project has developed a methodology and supporting documents in the form of an adaptable industrial course and a number of guide lines. By adapting the methodology lighter castings with shorter development times can be manufactured for all casting methods. This will strengthen both the end customers and the foundries. The methodology is of a generic nature can be used in other industries with the modification of industrial courses and guide lines.

Planned approach and implementation

The project consisted mainly of developing a methodology with associated industrial training for how process-related boundary conditions and process simulations are used in early development phases. This work was based on industrial requirements and components for both conventional casting and casting in 3D-printed molds. The methodology was demonstrated both by virtual and physical demonstrators. In order to facilitate the transition between optimization and process simulation, the topology optimization method CutFEM was also evaluated.