CASTING INNOVATIONS More Efficient Casting Process Simulation
Casting process simulation en- ables designers to determine manu- facturability, properties and estimated costs. By analyzing for potential defects early in the design phase, the costs associated with eliminating them can be reduced. MAGMA5
5.2, the latest release
from MAGMA Foundry Tech- nologies, Schaumburg, Ill., features more than 160 improvements to increase the efficiency of evaluating simulation results. It allows the direct comparison of
communication between production engineers and designers,” Heisser said. “For example, a new criterion to predict cracks allows the user to find stress- related casting quality problems more quickly. It is now also possible to quan- titatively assess casting distortion and compare these virtual measurements with the real part geometry.” Diecasting users will find an im-
Technical understanding of the entire process is achieved through three-dimensional visualization of the process at all points in time.
up to four different project versions. Filling, solidification and stress results can be animated in a synchronized mode. Users can quickly analyze proposed design alternatives, such as whether a feature on a casting should be cast as part of the design or if it should be machined in later. “A special highlight is the option to
display the geometry and all results in 3D stereo, using shutter or red/cyan 3D glasses, and to store them as 3D images
or movies,” said MAGMA President Christof Heisser. New result criteria allow for a more
effective evaluation of cooling and critical metal speeds during filling. Te progress of feeding and porosity formation can be monitored and displayed continuously during the entire solidification process. “Various new tools facilitate a stan- dardized result evaluation, improving the
proved visualization of the process time line and extended consideration of the heat transfer conditions. Te MAG- MAhpdc module supports assessing real casting temperature as a function of current shot sleeve conditions. A new “resume point” capability al-
lows flexibility in restarting the simula- tion with modified diecasting process conditions, based on the previous or next-to-last casting cycle. Sand casting processes can be
resumed with different conditions at the end of any process stage. Te automatic enmeshment of complex geometries has been simplified with new enmeshment criteria and procedures. MAGMA5
is modularly expandable
for specific processes, materials or qual- ity aspects: • MAGMAiron, MAGMAsteel, MAGMAnonferrous.
• MAGMAhpdc, MAGMAlpdc, MAGMApermanentmold, MAGMAwheel.
• MAGMAcore+mold, MAGMA-dielife.
• MAGMA HT thermal, MAGMA-stress, MAGMAlink. For the quantitative assessment of
casting distortion in the measurement perspective, it is now possible to compare the virtual measurement with the real part geometry. In addition, a new database of riser
sleeves, generated by ASK Chemicals, is now available. Casting process simulation allows designers to optimize designs by ensuring the desired material properties without maintaining excessive safety margins. It also facilitates communication between development, production, management, sales and casting buyers to ensure castable parts are produced according to customer
specifications and in a timely manner. Visit
www.magmasoft.com for more information.
54 | MODERN CASTING January 2013
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