Topology optimization of cast parts involving parting surface position is one of the main challenges in engineering design. This work presents a study on topology optimization of cast parts considering various cases of parting surface position. Two casting constraint models for different parting surface position requirements are developed and evaluated. One is a variable parting surface model to achieve the optimal castable design and parting surface position. Another is a virtual parting surface model for generating the required castable design with the user-specified parting surface position. The simple but efficient finite element method-based optimization algorithm is employed to simplify the optimization process. And the density filter-based threshold projection technique is utilized to enhance the 0–1 solution. Besides, the effects of the parting surface position, parting direction, loading path, and material volume on the resulting castable designs are investigated. Numerical examples are provided and compared with the existing methods to illustrate the effectiveness of the proposed method. This method does not depend on the fixed parting surface in the design domain as usual. Therefore, it can be used to produce high-performance castable designs with reasonable material layout and smooth boundaries.

涉及零件表面位置的铸件的拓扑优化是工程设计中的主要挑战之一。这项工作提出了一种考虑各种分离表面位置情况的铸造零件拓扑优化的研究。针对不同的分型面位置要求，开发并评估了两个铸造约束模型。一种是可变的分型面模型，以实现最佳的浇铸设计和分型面位置。另一个是虚拟的分型面模型，用于根据用户指定的分型面位置生成所需的可浇铸设计。采用简单但有效的基于有限元方法的优化算法来简化优化过程。并且基于密度滤波器的阈值投影技术被用于增强0-1解决方案。除了，研究了分型面位置，分型方向，加载路径和材料体积对所得可浇铸设计的影响。提供了数值示例，并与现有方法进行了比较，以说明所提方法的有效性。该方法通常不依赖于设计域中的固定分型面。因此，它可用于生产具有合理材料布局和平滑边界的高性能浇铸设计。