Abstract
Optimum casting designs are unreliable without consideration of the statistical and physical uncertainties in the casting process. In the present research, casting simulation is integrated with a general purpose reliability-based design optimization (RBDO) software tool previously developed at the University of Iowa. The RBDO methodology considers uncertainties in both the input variables as well as in the model itself. The output consists not only of a reliable optimum design but also of the knowledge of the confidence level in this design. An example is presented where the design of a riser is optimized while considering uncertainties in the fill level, riser diameter, and the riser pipe depth prediction. It is shown that the present reliability-based method provides a much different optimum design than a traditional deterministic approach.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
J. Kor, X. Chen, Z. Sun, H. Hu, “Casting Design through Multi-Objective Optimization,” Proc. of the 18th IFAC World Congress 2011, (2011), 6481–6486.
D.M. Liao, J.X. Zhou, L.L. Chen, X. Shen, and X.D. Gong, “Casting CAD/CAE Automatic Optimal Riser Design Technology,” Int. Journal of Cast Metals Research, 24 (2011), 247–252.
M. Sutaria, D. Joshi, M. Jagdishwar and B. Ravi, “Automatic Optimization of Casting Feeders Using Feed-Paths Generated by VEM,” ASME 2011 Int. Mech. Eng. Cong. and Expo., Volume 3: Design and Manufacturing (2011), 137–146.
R.S. Ransing, M.P. Sood, and W.K. Pao, “Computer Implementation of Heuvers’ Circle Method for Thermal Optimisation in Castings,” Int. Journal of Cast Metals Research, 18 (2005), 119–128.
MAGMA Gießereitechnologie GmbH, MAGMAfrontier Module Manuals: Part One, Part Two and Reference, (Aachen Germany, 2005).
I. Hahn and J.C. Sturm, “Autonomous Optimization of Casting Processes and Designs,” World Foundry Congress, Hangzhou, China October 16–20 (2010), 1–20.
I. Hahn and G. Hartmann, “Automatic Computerized Optimization in Die Casting Processes,” Casting Plant & Technology, No. 4 (2008), 2–14.
C. Tutum and J. Hattel, “State-of-the-Art Multi-Objective Optimisation of Manufacturing Processes Based on Thermo-Mechanical Simulations,” Chapter 3 in Multi-objective Evolutionary Optimisation for Product Design and Manufacturing, L. Wang et al. (eds.), (London England: Springer-Verlag, 2011), 71–133.
Finite Solutions Inc., OPTICast Training Course Workbook, Version 8.1.1 (2011).
Advanced Reasoning Technologies, AutoCAST Software User Manual and Case Studies, http://www.autocast.co.in, (2009).
B. Ravi, “Casting Simulation and Optimisation: Benefits, Bottlenecks, and Best Practices,” Indian Foundry Journal, 38 (2008), 47–52.
L. Zhao, K.K. Choi, and I. Lee, “Metamodeling Method Using Dynamic Kriging for Design Optimization,” AIAA Journal, 49 (2011), 2034–2046.
H. Song, K.K. Choi, and D. Lamb, “A Study on Improving Accuracy of Kriging Models by Using Correlation Model Selection and Penalized Log-Likelihood Function,” 10th World Congress on Structural and Multidisciplinary Optimization, May 20–24 Orlando, Florida, (2013).
I. Lee, K.K. Choi, Y. Noh, L. Zhao, and D. Gorsich, “Sampling-Based Stochastic Sensitivity Analysis Using Score Functions for RBDO Problems with Correlated Random Variables,” ASME Journal of Mechanical Design, 133 (2011), 021003.
I. Lee, K.K. Choi, and L. Zhao, “Sampling-Based RBDO Using the Stochastic Sensitivity Analysis and Dynamic Kriging Method,” Structural and Multidisciplinary Optimization, 44 (2011), 299–317.
E. Rigoni and S. Poles, “NBI and MOGA-II, Two Complementary Algorithms for Multi-Objective Optimization,” Practical Approaches to Multiobjective Optimization, (Dagstuhl Germany: Internationales Begegnungs- und Forschungszentrum für Informatik (IBFI), 2005), 1–22.
Author information
Authors and Affiliations
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2014 TMS (The Minerals, Metals & Materials Society)
About this chapter
Cite this chapter
Hardin, R., Choi, K.K., Beckermann, C. (2014). Reliability-Based Casting Process Design Optimization. In: Tiryakioğlu, M., Campbell, J., Byczynski, G. (eds) Shape Casting: 5th International Symposium 2014. Springer, Cham. https://doi.org/10.1007/978-3-319-48130-2_3
Download citation
DOI: https://doi.org/10.1007/978-3-319-48130-2_3
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-48594-2
Online ISBN: 978-3-319-48130-2
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)