MAGMA 5.4 Version
MAGMASOFT Autonomous engineering, DoE and new features in MAGMASOFT5.4 are becoming more powerful. Additional shot chamber simulation extended spraying options and optimized location of ejector pins are just additional points of interest for the HPDC industries while in the ferrous foundries the interest of core & mold and stress simulations are dominating. The quality standards of casting buyers are increasing, and the metal market is utmost competitive. To succeed in this competitive environment suitable design and process optimization tools are needed to avoid high reject rates and costly error & trials. Robust production processes are necessary to keep up with the high requirements. MAGMASOFT is certainly the right tool for optimizing the entire casting process and finally lead to customer satisfaction.
The new possibilities in MAGMASOFT® 5.4 allow for the detailed optimization of the spraying process. It is possible to carry out a detailed analysis of the surface temperatures of the die or evaluate the wetting of individual die areas for optimizing the casting quality regarding cold laps, porosity and die soldering. MAGMASOFT® 5.4 also allows for the evaluation of the distortion of die components or optimizing the local die lifetime. For the structural component, the simulation model was extended by a realistic representation of the spraying process including directional spray nozzles with spray cones, spray circuits and spraying cycle
--> Temperature curves in the die areas near the surface illustrate the effectiveness of the spraying process combined with internal die temperature control. The internal spot cooling in area 2 locally extracts energy from the die and minimizes the reheating of the die surface.
--> Optimized Cooling Different flow situations in the cooling line and their local heat transfer coefficients. The capillary tube used leads to an increase of the cooling capacity in the tip of the insert.
Realistic description of the spray
Representation of the spraying process including individual spray cones, spray circuits and spraying cycle with display of the local surface temperatures of the die in the course of the spraying process
Optimized Shot Chamber
Compares the optimized process conditions to the reduced simulation model without shot chamber. The nearly identical filling behavior of the two models confirms that the reduced (simplified) simulation model without shot chamber is equally represented for the upstream development process of the casting system. If required, the simulation model can be extended for a detailed analysis or process optimization of the processes in the shot chamber.