Review and Development of Manufacturing Design Constraints for Topology-Optimized Parts in Investment casting

Topology Optimization (TO), now a highly effective tool for generating lightweight, material-efficient designs, often extends design freedom to a degree that renders the resulting complex structures infeasible for traditional manufacturing processes. Investment casting, a versatile manufacturing method renowned for producing intricate geometries, encounters significant challenges in casting parts generated through TO due to the complex and unconventional geometries involved. This research aims to integrate topology optimization (TO) with investment casting by incorporating manufacturability considerations into the TO design phase. We see various approaches to incorporate casting constraints into the TO process, including simulation techniques such as 'Topshape', a "two-projected-field scheme", and a medial-axis-based approach for automating the reconstruction of TO designs. The research addresses challenges in manufacturability, casting constraints, and hot spot management in TO designs for investment casting. It proposes constraints to avoid hot spots and improve casting quality, providing specific design recommendations for investment casting of TO parts, emphasizing castable wall thicknesses and proper solidification patterns. Advanced techniques such as the Virtual Temperature (VT) method for avoiding enclosed voids and undercuts, integrating casting simulation into each iteration of the TO process, and using cubic filters to overcome unnatural thinning in TO designs are also explored. The study concludes by suggesting areas for future research, including developing more sophisticated TO constraints algorithms that inherently account for casting constraints and casting solidification behavior.

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Work Title Review and Development of Manufacturing Design Constraints for Topology-Optimized Parts in Investment casting
Access
Open Access
Creators
  1. Aranganathan Sankar
Keyword
  1. Topology optimization
  2. Investment casting
  3. Manufacturing process
License In Copyright (Rights Reserved)
Work Type Masters Culminating Experience
Sub Work Type Scholarly Paper/Essay (MA/MS)
Program Industrial Engineering
Degree Master of Science
Acknowledgments
  1. Dr. Robert Carl Voigt
Publication Date December 30, 2024
Deposited December 30, 2024

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Version 1
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  • Created
  • Updated
  • Updated Keyword, Publisher, Description, and 1 more Show Changes
    Keyword
    • Topology Optimization, Investment casting, Manufacturing process
    Publisher
    • Aranganathan Sankar
    Description
    • Topology Optimization (TO), now a highly effective tool for generating lightweight, material-efficient designs, often extends design freedom to a degree that renders the resulting complex structures infeasible for traditional manufacturing processes. Investment casting, a versatile manufacturing method renowned for producing intricate geometries, encounters significant challenges in casting parts generated through TO due to the complex and unconventional geometries involved. This research aims to integrate topology optimization (TO) with investment casting by incorporating manufacturability considerations into the TO design phase. We see various approaches to incorporate casting constraints into the TO process, including simulation techniques such as 'Topshape', a "two-projected-field scheme", and a medial-axis-based approach for automating the reconstruction of TO designs. The research addresses challenges in manufacturability, casting constraints, and hot spot management in TO designs for investment casting. It proposes constraints to avoid hot spots and improve casting quality, providing specific design recommendations for investment casting of TO parts, emphasizing castable wall thicknesses and proper solidification patterns. Advanced techniques such as the Virtual Temperature (VT) method for avoiding enclosed voids and undercuts, integrating casting simulation into each iteration of the TO process, and using cubic filters to overcome unnatural thinning in TO designs are also explored. The study concludes by suggesting areas for future research, including developing more sophisticated TO constraints algorithms that inherently account for casting constraints and casting solidification behavior.
    Publication Date
    • 2024-12-30
  • Updated Acknowledgments Show Changes
    Acknowledgments
    • Dr. Robert Carl Voigt
  • Added Creator Aranganathan Sankar
  • Added Aranganathan_Sankar_MS_Paper_TO_IC.pdf
  • Updated
  • Updated License Show Changes
    License
    • https://rightsstatements.org/page/InC/1.0/
  • Published
  • Updated
  • Updated Keyword, Degree, Program, and 1 more Show Changes
    Keyword
    • Topology Optimization, Investment casting, Manufacturing process
    • Topology optimization, Investment casting, Manufacturing process
    Degree
    • Master of Science
    Program
    • Industrial Engineering
    Sub Work Type
    • Scholarly Paper/Essay (MA/MS)
  • Updated Publisher Show Changes
    Publisher
    • Aranganathan Sankar