A simulation-based design paradigm for complex cast components

Stéphane P.A. Bordas*, James G. Conley, Brian Moran, Joe Gray, Ed Nichols

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

47 Scopus citations


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.

Original languageEnglish (US)
Pages (from-to)25-37
Number of pages13
JournalEngineering with Computers
Issue number1
StatePublished - Mar 2007


  • Casting design and modeling
  • Crack growth and damage tolerance analysis
  • Extended finite element method, XFEM
  • Industrial problems
  • Micro-macro simulations
  • Non-destructive evaluation

ASJC Scopus subject areas

  • Software
  • Modeling and Simulation
  • General Engineering
  • Computer Science Applications


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