PRODUCT RESOURCE FILE MAGMA – BUSINESS AMPLIFIED As the global leader in casting simulation solutions, MAGMA® is
committed to amplifying what’s possible for your industry. Considered the gold standard for predicting cast quality, MAGMA®
products
extend value throughout your entire foundry business. Taking our expertise in simulation, we partner with you to optimize every facet of your operation. Te result? Your casting business amplified.
Our latest product MAGMA5 tion product available. MAGMA5
is the most advanced casting optimiza- is the first toolset that acknowledges
your business doesn’t end at simulation; it ends at the balance sheet. MAGMA5
aspects of your business. Superior design, increased production, and stronger sales will result. Te bottom line, MAGMA5
ness… amplified. Starting from square one, MAGMA5
’s modular design allows you to use data to amplify all means busi-
optimizes the design process by
reducing excessive material usage, identifying early design flaws, and facilitating communication between your engineers, salespeople and clients. Fewer prototypes and trial runs, reduced down time, improved tool life, and reduced energy consumption elevate your production process to new levels of efficiency. Finally, sales and marketing will be amplified through seamless client-engineer communication, ac- cess to simulations for proposals, and the notoriety associated with ownership of MAGMA5
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business. By extending the quantitative and qualitative benefits of casting simulation through your entire process chain, profits and productivity are increased. Te question is simple: business as usual or your business amplified?
Contact us today to learn how to amplify your business. TECHNOLOGY IN ACTION
Columbia Steel reduces cleaning time with the help of MAGMASOFT®
User—Columbia Steel, Portland , Oregon
Operation—Founded in 1901, Columbia Steel has grown to become one of America’s leading manufacturer of steel alloy and iron alloy impact and wear resistant replacement parts and steel castings for basic industry. Establishing long-term partnerships with their custom- ers, the customer’s operations can benefit from improved equipment wear life, with lower processing costs as the result. Tis commitment to quality, backed up by a guarantee of proper fit, performance and dedication to customer satisfaction lead Columbia Steel in 2009 to the decision of implementing MAGMASOFT® into their operation.
Problem—A grinding table, which is the main support structure upon which in power plants coal is ground into powder using large wear resistant plates and rollers, is produced at Columbia Steel as a plain carbon steel casting that has a clean weight of 32,850 lbs. and a pour weight of 62,600 lbs. Prior to acquiring a seat of MAGMASOFT® the engineers at Columbia Steel designed a gating and risering system that produced castings free of solidification shrinkage indications. However, the parts made using this gating and risering system were spending more than 20 hours each in the cleaning room at Columbia Steel for repair work on gas pinholes, entrapped air or gas pockets, sand inclusions, slag inclusions, and sand penetration. In addition to the lengthy clean- ing times, the machining times for this part were also being extended to perform repair work when additional defects were revealed during machining. Interrupted cuts caused by the defects were also leading to poor tool life and increased down time for making tool changes.
Solution—First the filling using the original gating system was simulated. Tis baseline simulation revealed several undesirable conditions including a geyser effect that occurred as the metal shot into the mold cavity at velocities exceeding 165 in/s. Tis was causing excessive splashing and led to the formation of reoxidation inclusions and entrapped air and gases. In addition, the engineers noticed that the cavity was also filling from the 4 elevated ingates causing metal to cascade down from the top ingates to the metal level of the lower ingates. Te new gating system eliminated turbulence and entrapped air that occurred in the original design when the streams from each sprue collided in the main runner and also allowed Columbia Steel to coordinate the pouring into each sprue so that the ingates from the bottom of the part would fill up to the level of the higher ingates before the metal entered the top ingates.
16 ton grinding table produced at Columbia Steel
Benefits—Since making the changes to the gating system the de- fects originally observed have been almost completely eliminated. Te defect repair time that was over 20 hours per casting has been reduced to less than an hour per casting. Columbia Steel has also realized a 20% reduction in machining time on the grinding table. All gating systems designed at Columbia Steel are now developed using MAGMASOFT® filling simulations before being released to the shop floor. As a result, cleaning times have been reduced and the processing times for the cleaning room and machine shop are now more predictable, which makes scheduling less complicated.
Original gating system leading to oxides and inclusons
New gating system eliminates defects
MAGMA FOUNDRY TECHNOLOGIES 847-969-1001 Fax: 847-969-1003
www.magmasoft.com
info@magmasoft.com
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