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A simulation-based design paradigm for complex cast components

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Abstract

This paper describes and exercises a new design paradigm for cast components. The methodology integrates foundry process simulation, non-destructive evaluation (NDE), stress analysis and damage tolerance simulations into the design process. Foundry process simulation is used to predict an array of porosity-related anomalies. The probability of detection of these anomalies is investigated with a radiographic inspection simulation tool (XRSIM). The likelihood that the predicted array of anomalies will lead to a failure is determined by a fatigue crack growth simulation based on the extended finite element method and therefore does not require meshing nor remeshing as the cracks grow. With this approach, the casting modeling provides initial anomaly information, the stress analysis provides a value for the critical size of an anomaly and the NDE assessment provides a detectability measure. The combination of these tools allows for accept/reject criteria to be determined at the early design stage and enables damage tolerant design philosophies. The methodology is applied to the design of a cast monolithic door used on the Boeing 757 aircraft.

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Acknowledgments

The authors gratefully acknowledge the support of the FAA through FAA contract DTFA03- 98-F-IA025 Design and Quality Assurance of Premium Quality Aerospace Castings. Special thanks is extended to Xiaogong Lee, John Backuckas and Terry Khaled of the FAA for their support and availability throughout the project. The authors especially appreciated the direction, encouragement and support of the late Richard Topp of the Boeing Company.

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Authors and Affiliations

  1. Ecole Polytechnique Fédérale de Lausanne (EPFL), Institut des Structures, Laboratoire de Mécanique des Structures et des Milieux Continus (LSC), Station 18, 1015, Lausanne, Switzerland

    Stéphane P. A. Bordas

  2. Civil Engineering Department, University of Glasgow, Glasgow, G12 8LT, UK

    Stéphane P. A. Bordas

  3. Northwestern University, Kellogg School of Management, 5249 Jacobs Center, Evanston, IL, 60208-3111, USA

    James G. Conley

  4. Mechanical Engineering Department, Northwestern University, Evanston, IL, 60208, USA

    Brian Moran

  5. Iowa State University, Center for NDE, Ames, IA, USA

    Joe Gray

  6. Vought Aircraft Industries, Dallas, TX, USA

    Ed Nichols

Authors
  1. Stéphane P. A. Bordas
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  2. James G. Conley
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  3. Brian Moran
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  4. Joe Gray
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  5. Ed Nichols
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Correspondence to Stéphane P. A. Bordas.

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Bordas, S.P.A., Conley, J.G., Moran, B. et al. A simulation-based design paradigm for complex cast components. Engineering with Computers 23, 25–37 (2007). https://doi.org/10.1007/s00366-006-0030-1

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  • DOI: https://doi.org/10.1007/s00366-006-0030-1

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