Design sensitivity and finite element analysis of free surface flows with application to optimal design of casting rigging systems

McDavid, Robert M.; Dantzig, Jonathan A.

doi:10.1002/(sici)1097-0363(19980915)28:3<419::aid-fld721>3.0.co;2-4

Cited by 12 publications

(4 citation statements)

References 29 publications

(29 reference statements)

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“…The design of gating and riser systems is largely based on past experience and empirical rules [6,7] and simulation has become an important tool for the design, analysis and optimization of casting processes [8][9][10][11][12][13][14].…”

Section: Introductionsupporting

confidence: 73%

Casting Design through Multi-objective Optimization

Kor

Chen

Sun

et al. 2009

2009 Second International Conference on Future Information Technology and Management Engineering

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The gating and riser system design plays an important role in the quality and cost of a metal casting. Due to the lack of fixed theoretical procedures to follow, the design process is carried out on a trial-and-error basis. The casting design optimization problem is characterized by multiple design variables, conflicting objectives and a complex search space, making it unsuitable for sensitivitybased optimization. In this study, a formal optimization method using Multi-Objective Evolutionary Algorithm (MOEA) was developed to overcome such complexities. A framework for integrating the optimization procedure with numerical simulation for the design evaluation is presented. The proposed optimization framework was applied to the gating and riser system of a sand casting and the results were compared to a popular Design-ofExperiment (DOE) method. It showed that the MOEA method gave better results and provided more flexibility in decision making.

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Section: Introductionsupporting

confidence: 73%

Casting Design through Multi-objective Optimization

Kor

Chen

Sun

et al. 2009

2009 Second International Conference on Future Information Technology and Management Engineering

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“…The results are presented elsewhere. [29,39] The sensitivity formulation is checked by perturbing each design variable and estimating the sensitivity by finite difference. Errors of less than one part in 10 6 are typical.…”

Section: Direct Differentiation Methodsmentioning

confidence: 99%

“…Sections A and B describe the methods in sufficient detail to understand their use in this application and the reader is referred to the reference cited for full details. [29] A.…”

Section: Model Formulationmentioning

confidence: 99%

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Fluid flow in casting rigging systems: Modeling, validation, and optimal design

McDavid

Dantzig

1998

Metall Mater Trans B

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In this work, a methodology for the optimal design of flow in foundry casting rigging systems is discussed. The methodology is based on a novel, fully analytical design sensitivity formulation for transient, turbulent, free-surface flows. The filling stage of the casting process is modeled by solving the time-averaged form of the Navier-Stokes equations via a turbulent mixing-length model, in conjunction with the volume-of-fluid (VOF) method for modeling the free surface. The design of the runner and gating system of a simple block casting is presented as an example application for using sensitivity information in design. The analytical sensitivity routine is coupled to a numerical optimizer to yield an automated method for optimal design of the casting rigging system. The finite element model of the filling process is verified through physical experimentation. Solutions of glycerol and water are used to perform laminar and turbulent flow filling experiments, which are used to verify independently the VOF algorithm and the adequacy of the mixing-length model. The results show that the numerical model accurately reproduces the main features of the flow, and filling times agree with acceptable accuracy. Finally, the analytical techniques are used to obtain an optimal runner shape, which eliminates air entrainment, and the design is verified experimentally.

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Shape sensitivities in a Navier‐Stokes flow with convective and grey bodies radiative thermal transfer

Monnier¹

2003

Optim Control Appl Methods

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SUMMARYWe study a shape optimal design problem for a forced convection flow: the steady-state Navier-Stokes equations coupled with an integro-differential thermal model. The thermal transfers are convective, diffusive and radiative with multiple reflections (model of grey bodies, radiosity equation). The inverse problem consists in minimizing a smooth cost function which depends on the solution, with respect to the domain of the equations. We prove the differentiability of the solution with respect to the domain. It follows the cost function differentiability. We introduce the adjoint state equation and obtain the exact differential of the cost function. The computational method of shape sensitivities and the optimization process are presented too.

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Design sensitivity and finite element analysis of free surface flows with application to optimal design of casting rigging systems

Cited by 12 publications

References 29 publications

Casting Design through Multi-objective Optimization

Casting Design through Multi-objective Optimization

Fluid flow in casting rigging systems: Modeling, validation, and optimal design

Shape sensitivities in a Navier‐Stokes flow with convective and grey bodies radiative thermal transfer

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