Casting simulation analyses complex filling

May 8, 2006 – 12:45 pm

Latest casting simulation software includes a new ‘flow solver’, which enables the user to analyse complex filling conditions, and is also for components with extremely thin walls.
The new version of MAGMA’s casting simulation software, MAGMASOFT 4.4, has been available since early 2006. It includes an impressive collection of new features as well as possibilities to evaluate the simulation. The completely new flow solver enables the user to analyse complex filling conditions, also for components with extremely thin walls.

New criteria for the evaluation of the filling behavior can indicate potential defects resulting from the fluid flow behavior.

These criteria include, e g, the tracking of entrapped air and possible oxide inclusions during the filling or the evaluation of the casting performance of different gates.

Flow lengths can exactly be determined as well as the ‘age’ of the melt during the filling process.

Comprehensive information about the local heat balance for the tool can be created for the permanent mold casting process, which is important for the layout of cooling channels as well as for the thermal regulation of the die.

This allows the optimisation of the tool regarding productivity and die life time.

The high pressure die casting module MAGMAhpdc considers local squeezing.

The new version of the iron casting module MAGMAiron enables the user to predict mechanical properties of cast iron with compacted graphite.

Both, the module for tilt casting as well as the module for the simulation of the Rotacaster process are now considerably extended.

Using the module MAGMAlink the user can transfer MAGMASOFT results to various FE-programs.

Hence, the quality of crash, life time, and performance analyses can significantly be improved.

It is now possible for the first time to import scanned CT (computer tomography) data into MAGMASOFT and compare them with simulation results.

The completely new developed optimisation program MAGMAfrontier is the very first module that transforms a simulation program into a tool for process optimisation or optimised casting design.

* Advanced presentation tools - the new version includes an interesting collection of new features for the presentation of results.

The MAGMApost module visualizes, e g, vectors and air entrapments and allows the automatic creation of images and movies in various clippings.

Deformed casting geometries as well as pre-adjusted geometries can be exported.

The user can create individual criteria based on all MAGMASOFT results and can consequently adjust the results according to his specific needs.

The internal communication within the company as well as with customers is now supported by MAGMASOFT through a presentation composer.

The composer allows to create 3D objects and export animated presentations of the simulation results The freely available viewer to be downloaded from the MAGMASOFT homepage, on the Magma Web site, can be used to visualise such presentations and to interactively rotate, enlarge, or move geometries and results.

MAGMASOFT 4.4 is available for a wide suite of hardware platforms including Windows, Linux, and certain Unix Platforms from single processor versions up to parallelised cluster versions.

Summary: * Optimised filling solver for thin wall components.

* Comparison of simulation results and CT measurements in MAGMASOFT (courtesy of Ford research center, Aachen, Germany).

* Tracing the melt from different gates during the filling process.

* Tool distortion compared with the initial situation of the die.

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