The design of structural die casting components using topology optimization promises a time and resource efficient product development process. However, the development of a producible design is only possible with respect to process restrictions. Due to that, the presented approach suggests a link-up of topology optimization and process simulation. The initial optimization run is processed by a single form filling simulation in combination with a time-saving geometrical analysis, which identifies part regions with poor form filling. These regions are excluded from the design space for a second optimization run, which leads to an optimized geometry that includes process-related aspects. The new approach is exemplified and shows a distinct reduction of process critical part regions with comparatively low computing time. This promises an efficient generation of lightweight part designs with improved product features and an increase of process reliability, especially when the procedure is automated through software.     «

The design of structural die casting components using topology optimization promises a time and resource efficient product development process. However, the development of a producible design is only possible with respect to process restrictions. Due to that, the presented approach suggests a link-up of topology optimization and process simulation. The initial optimization run is processed by a single form filling simulation in combination with a time-saving geometrical analysis, which identifie...     »