A review of optimization of cast parts using topology optimization I – topology optimization without manufacturing constraints

In recent years, there has been considerable progress in the optimization of cast parts with respect to strength, stiffness, and frequency. Here, topology optimization has been the most important tool in finding the optimal features of a cast part, such as optimal cross-section or number and arrangement of ribs. An optimization process with integrated topology optimization has been used very successfully at Adam Opel AG in recent years, and many components have been optimized. This two-paper review gives an overview of the application and experience in this area. This is the first part of a two-paper review of optimization of cast parts. Here, we want to focus on the application of the original topology optimization codes, which do not take manufacturing constraints for cast parts into account. Additionally, the role of shape optimization as a fine-tuning tool will be briefly analyzed and discussed.