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We present a new efficient and robust algorithm for topology optimization of 3D cast parts. Special constraints are fulfilled to make possible the incorporation of a simulation of the casting process into the optimization: In order to keep track of the exact position of the boundary and to provide a full finite element model of the structure in each iteration, we use a twofold approach for the structural update. A level set function technique for boundary representation is combined with a new tetrahedral mesh generator for geometries specified by implicit boundary descriptions. Boundary conditions are mapped automatically onto the updated mesh. For sensitivity analysis, we employ the concept of the topological gradient. Modification of the level set function is reduced to efficient summation of several level set functions, and the finite element mesh is adapted to the modified structure in each iteration of the optimization process. We show that the resulting meshes are of high quality. A domain decomposition technique is used to keep the computational costs of remeshing low. The capabilities of our algorithm are demonstrated by industrial-scale optimization examples.
The desire to model in ever increasing detail geometrical and physical features has lead to a steady increase in the number of points used in field solvers. While many solvers have been ported to parallel machines, grid generators have left behind. Sequential generation of meshes of large size is extremely problematic both in terms of time and memory requirements. Therefore, the need for developing parallel mesh generation technique is well justified. In this work a novel algorithm is presented for automatic parallel generation of tetrahedral computational meshes based on geometrical domain decomposition. It has a potential to remove this bottleneck. Different domain decomposition approaches and criteria have been investigated. Questions regarding time and memory consumption, efficiency of computations and quality of generated surface and volume meshes have been considered. As a result of the work parTgen (partitioner and parallel tetrahedral mesh generator) software package based on the developed algorithm has been created. Several real-life examples of relatively complex structures involving large meshes (of order 10^7-10^8 elements) are given. It has been shown that high mesh quality is achieved. Memory and time consumption are reduced significantly, and parallel algorithm is efficient.