Topology optimization based on combined mechanical analysis and variable density method for casting structure

In this study, a topology optimization method based on combined mechanical analysis and variable density is presented for a large-scale casting structure with complex thin-walled structures. First, the mechanical analysis model of the frame is established, the first-order bending and torsional modes and stiffness values of the all-cast aluminum frame are obtained, and the basic mechanical parameters such as bending/torsional mode and stiffness constraints needed for topology optimization are defined. Using the variable density method, unneeded material that can be removed from the casting structure is identified. According to the design requirements, the optimization objective function and constraint conditions are established, and the variable density method is used to solve the problem. Analysis of the mechanical results before and after topology optimization reveals that the modes and stiffness values are larger than the target values, and the mass of the frame is reduced by 10.2 kg (i.e. 13.9%) compared with the original design. The application of the combined mechanical analysis and variable density method to a casting structure can effectively achieve lightweight design.