Manufacturing oriented topology optimization of 3D structures for carbon emission reduction in casting process

Low-carbon casting for box-beams is achieved by using an explicit topology optimization method that provides an optimized stiffener layout with fewer carbon emissions. First, a life-cycle assessment of carbon generated during casting stage is presented in detail. Considering the carbon assessment is formulated in an explicit form, an explicit topology optimization method is applied, where stiffeners are explicitly described with geometric parameters. Additionally, the stiffeners are able to move freely without background mesh constraints. This trait is achieved by an interpolation algorithm that spreads the stiffness of the stiffeners to adjacent background nodes. To illustrate this method, a press slide is investigated, and the optimized design shows a 17.6% reduction in carbon emissions with no reduction of stiffness.