A Review of Topology Optimization Methods and Their Application in Foundry Production
Published: 06.05.2026
Authors: Svintsitskiy F.S., Korotchenko I.A.
Published in issue: #5(173)/2026
Category: Metallurgy and Science of Materials | Chapter: Metal Science, Thermal Processing of Metals and Alloys
Modern mechanical engineering is characterized by growing demands for the efficiency and cost-effectiveness of production processes. One promising approach addressing these challenges is Topology Optimization (TO). This work provides a comprehensive analysis of the methods and practical application of topology optimization in the die casting process. Fundamental TO algorithms for solids (SIMP, BESO) and fluid flows (the Brinkman penalization method for variable porosity), as well as auxiliary methods and algorithms for optimizing the design variable (MMA, OC, SQP), are considered. Particular attention is paid to the formulation of objective functions for minimizing hydraulic and thermal losses in runner systems. Using specific examples, the effectiveness of TO for solving practical problems is demonstrated: optimizing part geometry and designing runner and gating systems. It is shown that the implementation of these methods allows for a significant reduction in material usage, minimization of casting defects, and an increase in tooling service life. In conclusion, unresolved issues are formulated, such as the need to account for turbulence and manufacturing constraints, which define directions for future research. The conducted analysis confirms the high potential of topology optimization for automating and increasing the efficiency of die casting processes.
EDN YLNHGI
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