Development of a physical geometry analysis for manufacturable topology optimized castings.

本研究项目提出了一种方法，在考虑生产过程的情况下，利用拓扑优化从根本上改善铸造零件设计的最新工艺。在经过拓扑优化和随后的人工重建之后，必须在产品开发过程的每次迭代中模拟几何形状，以确保可制造性。这个连续的过程必须重复，直到在功能和过程之间达到令人满意的折衷。在此基础上，阐述了一种基于物理元模型的拓扑优化与快速铸造工艺评价相结合的新方法。通过将元模型集成到优化环境中，通过减少人工重建循环的数量和所需的过程模拟，可以节省大量的时间。

This research project addresses an approach to fundamentally improve the state of the art procedure for the design of casting partsusing topology optimization under consideration of the production process. After passing through a topology optimization andsubsequent manual reconstruction, the geometry has to be simulated within every iteration of the product development process to ensure manufacturability. This sequential procedure has to be repeated until a satisfactory compromise between function and process is achieved. On this basis, a new approach for the combination of topology optimization and fast casting process evaluation based on a physical meta model will be explained. By integration of the meta model into the optimization environment, considerable time savings are achieved by reducing the number of manual reconstruction loops and thus process simulations needed.