Skip to main content
Log in

Optimal riser design in sand casting process by topology optimization with SIMP method I: Poisson approximation of nonlinear heat transfer equation

  • Research Paper
  • Published:
Structural and Multidisciplinary Optimization Aims and scope Submit manuscript

Abstract

The optimal design of a casting feeding system is considered. The problem is formulated as the volume constrained topology optimization and is solved with the finite element analysis, explicit design sensitivity, and numerical optimization. In contrast to the traditional topology optimization where the objective function is defined on the design space, in the presented method, the design space is a subset of the complement of the objective function space. To accelerate optimization procedure, the nonlinear unsteady heat transfer equation is approximated with a Poisson-like equation. The feasibility of the presented method is supported with illustrative examples.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  • Allaire G (2001) Shape optimization by the homogenization method. Springer Verlag

  • Bendsøe M (1989) Optimal shape design as a material distribution problem. Struct Multidisc Optim 1(4):193–202

    Google Scholar 

  • Bendsoe M, Kikuchi N (1988) Generating optimal topologies in structural design using a homogenization method. Comput Methods Appl Mech Eng 71(2):197–224

    Article  MathSciNet  Google Scholar 

  • Bendsøe M, Sigmund O (1999) Material interpolation schemes in topology optimization. Arch Appl Mech 69(9):635–654

    Article  Google Scholar 

  • Bendsoee M, Sigmund O (2004) Topology optimization: theory, methods and applications. Springer

  • Harzheim L, Graf G (2005) A review of optimization of cast parts using topology optimization I—topology optimization without manufacturing constraints. Struct Multidisc Optim 30:491–497

    Article  Google Scholar 

  • Harzheim L, Graf G (2006) A review of optimization of cast parts using topology optimization II—Topology optimization with manufacturing constraints. Struct Multidisc Optim 31:388–399

    Article  Google Scholar 

  • Huy H, Argyropoulosz S (1996) Mathematical modelling of solidification and melting: a review. Modelling Simul Mater Sci Eng 4:371–396

    Article  Google Scholar 

  • Lewis R, Ransing R (1997) Optimal design of die coating thickness using the Lewis-Ransing correlation. Int J Cast Met Res 9:269–277

    Google Scholar 

  • Lewis R, Ravindran K (2000) Finite element simulation of metal casting. Int J Numer Methods Eng 47:29–59

    Article  MATH  Google Scholar 

  • Lewis R, Manzari M, Ransing R, Gethin D (2000) Casting shape optimisation via process modelling. Mater Des 21(4):381–386

    Google Scholar 

  • Lewis R, Manzari M, Gethin D (2001) Thermal optimisation in the sand casting process. Eng Comput 18(3/4):392–417

    Article  MATH  Google Scholar 

  • Manzari M, Gethin D, Lewis R (2000) Optimisation of heat transfer between casting and mould. Int J Cast Met Res 13(4):199–206

    Google Scholar 

  • Morthland T, Byrne P, Tortorelli D, Dantzig J (1995) Optimal riser design for metal castings. Metall Mater Trans B 26(1–2):871–885

    Article  Google Scholar 

  • Neises S, Uicker J, Heine R (1987) Geometric modeling of directional solidification based on section modulus. AFS Trans actions 95:25–30

    Google Scholar 

  • Ravi B (2005) Metal casting: computer aided design and analysis. Prentice Hall of India, India

    Google Scholar 

  • Ravi B, Srinivasan M (1996) Casting solidification analysis by modulus vector method. Int J Cast Met Res 9:1–7

    Google Scholar 

  • Rozvany G, Zhou M (1990) Applications of the COC algorithm in layout optimization. In: Engineering optimization in design processes, Proc Int Conf Karlsruhe, Germany, pp 59–70

  • Rozvany G, Zhou M, Birker T (1992) Generalized shape optimization without homogenization. Struct Multidisc Optim 4(3):250–252

    Google Scholar 

  • Singh D, Mallinson G, Panton S (2002) Applications of optimization and inverse modeling to alloy wheel casting. Numer Heat Transf A 41(6):741–756

    Article  Google Scholar 

  • Tartar L (2000) An introduction to the homogenization method in optimal design. In: Cellina A, Ornelas A (eds) Optimal shape design. Lecture notes in maths, vol 1740. Springer, pp 47–156

  • Tavakoli R, Davami P (2007a) A fast method for numerical simulation of casting solidification. Commun Numer Methods Eng, doi:10.1002/cnm.1062 (in press)

  • Tavakoli R, Davami P (2007b) Unconditionally stable fully explicit finite difference solution of solidification problems. Metall Mater Trans B 38(1):121–142

    Article  MathSciNet  Google Scholar 

  • Tortorelli D, Michaleris P (1994) Design sensitivity analysis: overview and review. Inverse Probl Eng 1(1):71–105

    Article  Google Scholar 

  • Tortorelli D, Tomasko J, Morthland T, Dantzig J (1994) Optimal design of nonlinear parabolic systems. Part II: Variable spatial domain with applications to casting optimization. Comput Methods Appl Mech Eng 113(1-2):157–172

    Article  MathSciNet  MATH  Google Scholar 

  • Zabaras N, Ruan Y, Richmond O (1992) On the design of two-dimensional Stefan processes with desired freezing front motions. Numer Heat Transf 21:307–325

    Article  Google Scholar 

  • Zhou M, Rozvany G (1991) The COC algorithm, Part II: Topological, geometrical and generalized shape optimization. Comput Methods Appl Mech Eng 89(1–3):309–336

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Rohallah Tavakoli.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Tavakoli, R., Davami, P. Optimal riser design in sand casting process by topology optimization with SIMP method I: Poisson approximation of nonlinear heat transfer equation. Struct Multidisc Optim 36, 193–202 (2008). https://doi.org/10.1007/s00158-007-0209-0

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00158-007-0209-0

Keywords

Navigation