Engineering with Computers

, Volume 23, Issue 1, pp 25–37

A simulation-based design paradigm for complex cast components

  • Stéphane P. A. Bordas
  • James G. Conley
  • Brian Moran
  • Joe Gray
  • Ed Nichols
Original Article

DOI: 10.1007/s00366-006-0030-1

Cite this article as:
Bordas, S.P.A., Conley, J.G., Moran, B. et al. Engineering with Computers (2007) 23: 25. doi:10.1007/s00366-006-0030-1


This paper describes and exercises a new design paradigm for cast components. The methodology integrates foundry process simulation, non-destructive evaluation (NDE), stress analysis and damage tolerance simulations into the design process. Foundry process simulation is used to predict an array of porosity-related anomalies. The probability of detection of these anomalies is investigated with a radiographic inspection simulation tool (XRSIM). The likelihood that the predicted array of anomalies will lead to a failure is determined by a fatigue crack growth simulation based on the extended finite element method and therefore does not require meshing nor remeshing as the cracks grow. With this approach, the casting modeling provides initial anomaly information, the stress analysis provides a value for the critical size of an anomaly and the NDE assessment provides a detectability measure. The combination of these tools allows for accept/reject criteria to be determined at the early design stage and enables damage tolerant design philosophies. The methodology is applied to the design of a cast monolithic door used on the Boeing 757 aircraft.


Casting design and modeling Extended finite element method, XFEM Crack growth and damage tolerance analysis Non-destructive evaluation Industrial problems Micro–macro simulations 

Copyright information

© Springer-Verlag London Limited 2006

Authors and Affiliations

  • Stéphane P. A. Bordas
    • 1
    • 2
  • James G. Conley
    • 3
  • Brian Moran
    • 4
  • Joe Gray
    • 5
  • Ed Nichols
    • 6
  1. 1.Ecole Polytechnique Fédérale de Lausanne (EPFL), Institut des StructuresLaboratoire de Mécanique des Structures et des Milieux Continus (LSC)LausanneSwitzerland
  2. 2.Civil Engineering DepartmentUniversity of GlasgowGlasgowUK
  3. 3.Northwestern University, Kellogg School of ManagementEvanstonUSA
  4. 4.Mechanical Engineering DepartmentNorthwestern UniversityEvanstonUSA
  5. 5.Iowa State University, Center for NDEAmesUSA
  6. 6.Vought Aircraft IndustriesDallasUSA

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