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

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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.