PRODUCT RESOURCE FILE “Casting Fascination”
TECHNOLOGY IN ACTION MAGMASOFT®
helps May Foundry & Machine Co. to
prove better casting design to customer User—May Foundry & Machine Co., Salt Lake City, Utah
several new simulation capabilities: new process modes for per- manent mold, low pressure sand and low pressure die casting, as well both hot-chamber and cold-chamber die casting allow for detailed process-specific definitions. MAGMA5
ports process design by controlling process parameters during a simulation run. Newest developments include the quantitative prediction of as-cast and heattreated local microstructures and properties in aluminum, iron and steel castings. MAGMA5 simulates sand and reoxidation inclusions during mold filling and predicts defects related to molding materials.
also sup-
MAGMA5 MAGMA5
- Optimized Reality , the latest release of MAGMASOFT® , introduces
Operation—May Foundry & Machine is a job shop specializing in small to medium production runs of custom geometries and com- plex ferrous metals servicing many industries including agriculture, mining, defense, transportation, and material processing. Currently, about 70% of production is cast in stainless, low carbon, low alloy, and high alloy grades of steel. Te other 30% are poured in grey and white iron, as well as abrasion resistant irons and ductile in all but austempered grades. Being a small job shop, MAGMASOFT® is used as a marketing tool to differentiate May Foundry & Machine from others in the local market, as a tool for efficient pattern set up for new jobs, a tool in root cause analysis, and to optimize many of the old patterns. May Foundry & Machine has a methodology set to have at least one continuous project going through simulation amongst the new jobs at any time, but also makes an efforts to improve not only the new jobs they get but also current jobs.
Problem—A knife block holder job was one that was once viewed as a complex job with stringent customer requirements for geometry that did not lend itself well to casting soundly. Asking the customer for geometry changes to lend itself to better castability was a risky proposition.
Solution—With MAGMASOFT®, May Foundry & Machine was able to try many different solutions and prove the changes before they went to the customer. Changing a simple fillet radius, with the permis- sion of the customer, and added chills actually reduced the amount of feed metal, resulting in a more sound casting with no visible defects.
Benefits—Modeling the proposed layout in MAGMASOFT® allowed May Foundry & Machine to prove to its customer that a design change will provide the desired casting quality within the required delivery timeframe. Te customer was happy with May Foundry & Machine being able to meet the expedited delivery schedule with little problem due to the absence of the rework welding loop.
MAGMA Core+Mold – Transparency in Core Production
MAGMA C+M is an integrated tool for the simulation of core production processes to simulate core shooting, blowing, and hardening of organic and inorganic cores. Processes where binder hardening is driven by a catalyst gas, as well as core production with tempered core boxes are supported. MAGMA C+M considers all aspects of core production starting from the core shooter, in order to calculate the flow of the air-sand mixture based on the real shot parameters. An integrated database provides the ability to specify the characteristics of the sand and the binder system as well as core box vents and blow tubes gassing. MAGMA C+M takes advantage of all the functionality of MAGMA5 module to MAGMA5
or as a stand alone product. and is available as an add-on
MAGMA FOUNDRY TECHNOLOGIES 847/969-1001 Fax: 847/969-1003
www.magmasoft.com
info@magmasoft.com
METALCASTING EQUIPMENT, PRODUCTS & SERVICES 2011-12 9
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