At left, the customer’s casting design produced 100% cracks in several locations in these rib areas. At right, Dalton used a stress simulation to show the customer the crack was built into the design and not caused by poor foundry practice.


design. Unfortunately, the crack ap- peared in the fi rst prototype poured. “We went through several gating


design changes and process changes to see if there was a way to eliminate


the crack,” said Rob Burita, tooling engineer at Dalton Foundry. “Every time we ran one of the changes, we still had the crack. We started realiz- ing it was something inherently built


into the design of the part.” Due to the nature of the crack


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and its location at the corner of the rib, Burita suspected it could be caused by stress during solidifi cation. Dalton Foundry attempted to alter the design of the casting on its own by manually fi ling the core to alter its shape, but the crack persisted. T e metalcaster now had the unpalatable task of telling the customer their design was the culprit. “We knew there would be a


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pretty signifi cant design change,” Burita said. Recently, Burita had been exposed to the MAGMAstress extension module for use in casting process modeling, and he knew it would help identify what was causing the stress and how to resolve it. Although it ran MAGMA solidification software, Dalton Foundry did not own that particular stress module. “After we exhausted all the


process, gating and design changes and had a pretty good suspicion it was stress-related, we finally went to the customer and said, based on our experience with the stress simulation, we think we need to run the part in the stress pro- gram,” Burita said. The customer agreed and


Dalton obtained the software to use through the design iterations of the part. According to Burita, the first simulation in the stress


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