Development of a data-driven process-oriented geometry optimization for the sand and gravity die casting of aluminum

• Applicants: Dr.-Ing. Christoph Hartmann; Professor Dr.-Ing. Stephan Tremmel; Professor Dr.-Ing. Wolfram Volk
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 538901188

The great freedom of design in the construction of cast components predestines the use of structural optimization methods for the load-oriented design of components. Currently, structural optimization takes casting requirements into account - if at all - by using rudimentary manufacturing constraints. Current examples of manufacturing constraints for casting processes are draft angles, the avoidance of undercuts, and extrusion or symmetry boundary conditions. An alternative to this is the integration of process knowledge in the form of full casting simulations into the TO process. Both approaches currently still have limitations. For example, the consideration of manufacturing restrictions limits the mapping of the actual casting process, and the mapping by means of full-fledged casting simulations is associated with high computational costs. The current research project aims at the integration of process knowledge of gravity-driven casting processes in structural optimization by means of data-driven models with low computation times in order to enable thereby an application with reduced computational requirements in optimization loops. With the help of this method, the possibility is created to generate load-optimal component structures, whereby the requirements of the casting process are already taken into account during the structural optimization. In the process, the design freedom is successively reduced with increasing geometry definition.

• DFG Programme: Research Grants
• Co-Investigator: Professor Dr.-Ing. Frank Rieg