New Release MAGMASOFT® 5.5

Benefits for Users and Decision Makers – the New MAGMASOFT® 5.5

 

With the release of MAGMASOFT® 5.5, you can look forward to innovative new capabilities. Efficient casting development, reliable starts of production and robust process windows – numerous new options in the release 5.5 allow for creating even more value in casting design, in toolmaking and in the foundry. Particular emphasis has been placed on further simplified and efficient use of the software and its results.

Thermal convection during solidification influences the feeding behavior

-->  Cast Iron in Motion

Completely new capabilities are available to iron foundrymen to consider the effects of metallurgy and metal treatment on solidification and feeding behavior. With the innovative SMAFEE feeding algorithm, the influence of melt quality, inoculation practice and local pressure distributions on porosity development is even better taken into account. In addition, thermal convection during solidification is now calculated as a standard for iron castings. The impact of the flow on the resulting temperature profile influences the feeding behavior both, large castings and in series production.

 

The “heart” of the optimized MAGMAIron module is the SMAFEE feeding algorithm. Pressure differences in the metal are created through the combination of metallostatic pressure, local austenite shrinkage and graphite precipitation and the rigidity of the mold. The software calculates local metal transport in partially solidified regions of the casting and the resulting ability to feed the solidifying iron. Thus, both metal quality and inoculation state influence feeding and shrinkage formation in the casting.

 

The new feeding model is available for all types of cast iron: Grey, ductile and compacted graphite iron.

Direct evaluation of different casting defects in comparison

with CT (Blue: Entrapped  air / Red: shrinkage porosities)

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-->  Quality Assessment in Die Casting 
In high pressure die casting, casting defects due to entrapped air combined with shrinkage porosities are major causes for scrap. Tooling and process design therefore focus very strongly on reducing porosity due to entrapped gases and shrinkage. The mass balance of air in the cavity and the transport of entrapped air can reliably predicted using MAGMASOFT® 5.5. In the new “Air” result, the amount of air in the cavity and in the melt is visualized quantitatively and allows complete assessment over the entire filling process. It is possible to consistently evaluate the quality of the tooling design and the process conditions over the course of a project, even under changing situations. The corresponding masses of air and well as the effectiveness of the venting conditions can be quantitatively tracked over time using calculated curves.
In addition the prediction of feeding during the intensification phase has been improved. Thus, for the first time, all potential defects in the casting (Caused by both air entrapment and shrinkage porosity) can be evaluated using a single result. This also allows a direct comparison with CT measurements.

The Crooked Core

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Core distortion during filling of an electric motor housing

-->  The Crooked Core

With the progressive necessity for lightweight designs and the resulting thinner wall sections, core-related casting defects due to distortion or core breakage are increasing.

MAGMASOFT® 5.5 now provides for the first time the possibility to predict and avoid stresses in the core during filling and solidification. This allows to prevent casting defects due to core distortion or failure. During the mold filling the cores heats up and is subject to mechanical forces due to buoyancy. As cores expand during the solidification it may be confined by the core marks, resulting in distortion or even breakage. In the analysis the constantly changing material properties of the core are considered.

The prediction of core distortion has been developed and validated with well-known industry and university partners. Extensive material data is available for various sand/binder combinations. In addition to cold box cores, particular attention has been paid to predict the distortion behavior of inorganic cores.

The unique capabilities provide increased security in avoiding core breakage, allow the prediction of local dimensional tolerance and enable the pre-compensation of core distortion through modification of core-box designs. Unnecessary costs can be avoided via a systematic tooling and process development.

Optimized Heat Treatment of Steel Castings

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-->  Optimized Heat Treatment of Steel Castings

Optimized Heat Treatment of Steel Castings

MAGMASOFT® 5.5 enables the optimization of heat treatment for a wide range of low and high alloy steel grades. This makes it possible to check whether the process conditions and the resulting local microstructure and mechanical properties of the component meet the customer's requirements. In addition to new results to assess cooling rates in critical temperature ranges, the program now considers the austenitic grain growth. A unique feature is the possibility to transfer the segregation-related local composition from the casting process to the heat treatment calculation.

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MAGMA CC – Now Also Available for Steel

-->  MAGMA CC – Now Also Available for Steel

MAGMA CC can now also be used even more efficiently for all continuous steel casting processes. Numerous extensions are available for the optimization of the start-up process and for the thermal and mechanical calculation of the process – also for bow-type casters. The fully integrated capabilities for virtual designs of experiments and autonomous optimization allow the user to assess robust manufacturing conditions while ensuring material quality by monitoring inclusions or avoiding core cracks.

MAGMASOFT® 5.5 – Faster to the Goal Overall

The use of the software should support the user's daily work routine easily and effectively. The time to solution must be as short as possible. MAGMASOFT® 5.5 offers many improvements in usability to get to the required results faster and allows assessing them quantitatively. With the extended integration of MAGMAinteract®, communication and exchange of results within the company and with customers becomes even more self-evident.

MAGMASOFT® 5.5 thus offers diverse and new potentials for securing and increasing the efficiency of casting design, tooling layouts or production processes for both, users and decision makers.