i casting design and engineering - · pdf filecomplete solution for profitable high quality...

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COMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking -i Casting process optimization -i Quality control and reliable production —i Cost savings Committed to Casting Excellence

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Page 1: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

COMPLETE SOLUTION FOR PROFITABLE

HIGH QUALITY CASTINGS

- i Casting design and engineering

- i Gating and risering

- i Reliable tool and patternmaking

- i Casting process optimization

- i Quality control and reliable production

—i Cost savings

Committed to Casting Excellence

Page 2: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

MAGMA5 is the comprehensive and effective simulation tool for improving casting quality, optimizing process con­ditions and substantially reducing costs in the foundry. MAGMA5 is designed to predict total casting quality by simulating mold filling, solidification and cooling, and optionally stresses/strains as well as microstructure formation and property distributions in casting manu­facturing processes.

With its modular design, MAGMA5 contributes to cost re­duction along the complete process chain of a cast com­ponent: from conceptual to final component design, tool­ing layout and prototyping, all the way through to process optimization, reliable production and quality management.

Temperature distribution in the melt during mold filling

Casting quality is defined by numerous differing require­ments and is affected by numerous processes during casting production. MAGMA5 is designed to support all aspects of casting manufacture, from casting design, melting and metallurgy, pattern and mold making, and casting itself through to heat treatment, fettling and repair.

MAGMA5 can be used for all cast materials, ranging from gray iron, sand and die cast aluminum, to large steel castings. MAGMA5 is also applicable to all casting pro­cesses, for example allowing the die caster to optimize tooling designs, minimize cycle times and predict defect formation all before tool steel is cut.

SIMPLY PROFITABLE

The cost benefits of using MAGMA5 in the foundry or in design are: —i Reduction of quality costs by avoiding casting

defects that arise from misruns, turbulence, oxide and slag entrainment, gas porosity, and shrinkage

—i Optimization of the filling process to provide a fast and controlled flow

—i Saving time during the design and dimensioning of ingates, runners and vents, as well as risers, chills and other feeding aids

—i Cost reduction in all areas, from material usage through productivity, quality, and energy costs

—i Reduction of cycle times by optimizing heating and cooling lines

—i Supporting the expert by verifying process para­meters and predicting robust production windows

Thermal modulus for fast riser layout

— i Increased security by checking operating points and through proven process conditions

—i Minimization of start up costs caused by gating, riser, and process layout modifications

—i Connects using latest communication technologies, within your company and in cooperation with custo­mers

—i Increased customer confidence through the proac­tive demonstration of foundry competence using this innovative tool

Page 3: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

OPTIMIZED REALITY

Solidification patterns show critical areas in the casting

COMPLETE, MODULAR AND EXTENDABLE

MAGMA5 standard has a modular structure and inclu­des all the functionality required for comprehensive cast­ing process simulation. The software makes it possible to work interactively and intuitively in multiple perspec­tives simultaneously. The basic structure of MAGMA5

consists of the following features: —i Common graphical user interface for all modules —i Project management perspective for handling of project

versions

— i Geometry perspective using a solid modeler based on a CAD kernel and optionally import/export of CAD data

—i Mesh perspective offering an automatic enmeshment of the geometry for simulation

—i Definition perspective for the complete definition of the relevant material, heat transfer, process and simulation parameters

—i Simulation solvers for calculation of pouring, solidifica­tion and cooling, including series casting simulation

—i Result perspective for comprehensive visualization and evaluation of simulation results

—i Database module to manage thermophysical and other relevant process data required for simulation

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Prediction of feeding and porosity

GEOMETRY PERSPECTIVE INCLUDING SOLID MODELING AND FULLY AUTO­MATIC ENMESHMENT

The geometry perspective comprises a solid modeler for fast and easy creation of complex shaped casting and mold geometries. All parts of the geometry can be mani­pulated. This allows rapid modifications of e.g. the gating and feeding system based on the results of previous si­mulation runs.

Gating and risering design

The solid modeler can be used e.g. for the design of cool­ing channels in permanent molds, riser sleeves and chills in steel castings and the easy construction of multiple ca­vity dies. The optional standard and direct CAD interfaces allow geometries constructed within different CAD sys­tems to be imported and modified, or geometry created in MAGMA5 to be exported for use in CAD.

Easy import and modeling of complex tool designs

In the mesh perspective, an enmeshment of the casting and mold geometry can be created fully automatically within mi­nutes. Accuracy and coarseness of the mesh can be adjus­ted by the user through globally defined parameters.

Page 4: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

SETTING UP THE PROCESS

The definition perspective supports the definition of the casting process parameters and other definitions required for the simulation. The appearance of the perspective changes based on the selected casting process (sand casting or die casting).

Process specific definitions for sand casting

For gravity sand castings, the casting process definitions allow the specification of: —i Pouring conditions at the inlet including a wizard to

support the definition of pouring conditions for bottom pour ladles

—i Stop conditions for the solidification simulation —i Shake-out conditions from the mold and further cooling

Definition of the Pouring Rate

Speefy ttte telle and the calculation parameters to determne the pourtig rate.

Ladle Data (project/Ladle Data)

CapaeSy Ladle Diameter [D] | NOZ&S Diameter [d] Taper [afctia] |

Cafcufetten Parameters Cas&ig and rigging system Current amount of melt m adle Current part to be cast Distance from ladte to Inlet [hj Dfechaf ge coefficient 5eG»n area of Wet Est section area of stream at Ink C^cuiated pourttg Urne

Load Ladle Data Save Ladle Data

Wizard to determine the discharge from a ladle

The steps in the casting process and other simulation definitions can be directly accessed: —i Material definition with initial or pouring temperatures of

the materials —i Automatic definition of heat transfer between material

pairs which are present in the geometry —i Display of all casting process phases and steps using

pictograms, durations and points in time shown in an interactive process timeline

—i Flexible result selection and options for accelerated result visualization

— i Specification of physical models or phenomena to be considered in the simulation, coupled to the correspon­ding process and result definitions

—i Start, dump, stop and restart options for mold filling and solidification simulations at any time

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For die castings, the casting process definitions allow the specification of: —i Number of heating cycles and production cycles to be

simulated —i Die closing time and delay between die closing and

pouring — i Pouring conditions at the inlet —i Die opening times individually for each die section —i Delay between die opening and casting ejection

For both processes, it is possible to specify and simulate further handling of the casting such as: —i Trimming of the gating system or feeders —i Quenching conditions for given quench media and

temperatures —i Multiple machining steps after shake-out

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Process specific definitions for die casting processes

Page 5: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

OPTIMIZED REALITY

FLUID FLOW MODULE MAGMAFILL

The MAGMAfill module allows the investigation of the flow and filling pattern in the cavity coupled with heat flow in both dies and molds for all shaped castings.

The mold filling simulation is based on the solution of the Navier-Stokes' equations for fluid flow and mold filling processes using latest technology to track the metal free surface. The melt viscosity and surface tension are taken into account. MAGMAfill uses accurate algorithms to consider the exact position of the metal/mold interface and the corresponding wall friction. The escape of gases from the cavity through vents or permeable sand and the corresponding back pressure on the melt is calculated.

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Metal temperatures during mold filling

MAGMAfill offers the following information: —i Mold filling sequence considering surface tension and

melt turbulence —i Local melt velocities and pressures —i Visualization of melt turbulence through tracer partic­

les with size and mass —i Cooling of the melt and the temperature distribution

at all times during pouring —i Criteria indicating areas in danger for cold laps, mis-

runs, and mold erosion as well as entrapped gases —i Display of the filling behavior of the gating system and

prediction of local flow lengths in the casting —i Prediction of the contact times of the melt with the en­

vironment —i Visualization of the back pressure in the cavity as well

as prediction of gas entrapment and transport —i Pouring times, local flow rates and sensors for tempe­

ratures, pressures and velocities

Temperature distribution in the metal and the die during mold filling

MAGMAfill assists the foundryman in the following objectives: —i Optimization of gating systems —i Prediction of sand erosion and penetration due to

critical velocities of the melt —i Determination of filling times based on the gating

system geometry —i Optimal placement of vents and overflows in

die casting —i Investigation of turbulence within the melt causing

entrapment of slag or oxide inclusions —i Effective use of filters

Tracer particles with mass and size show turbulence in the melt

Page 6: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

HEAT FLOW AND SOLIDIFICATION MODULE MAGMASOLID

MAGMAsoWd is a powerful tool for the investigation of casting solidification and cooling. It takes into account liquid and solid contraction to show the feeding of the casting and porosity formation.

Hot spots in the casting shown in X-ray mode

MAGMAsotid provides information about the following: —i Solidification patterns and feeding paths —i Solidification times, temperature gradients and

cooling rates at all points in the casting —i Criteria to predict critical regions within the casting

such as gross shrinkage, centerline shrinkage and microporosity

—i Thermal loading of dies, cores and molds —i Tendency for burn-on and penetration —i Cooling curves at any location within the casting,

mold or die

MAGMAsotid assists the foundryman in the following objectives: —10ptimal methoding of castings and the layout of

permanent molds and dies —i Quantitative determination of feeding requirements

for any casting section, as well as the feeding effec­tiveness of risers (sand, insulated or exothermic)

—i Minimization and effective use of chills —i Investigation of process conditions such as optimal

time to remove the casting, cooling needs of the mold material, effects of chilling, heat impact on cores

A look inside the die including cooling lines

DIE CASTING PROCESS SIMULATION MODE

The die casting process mode provides the capability for modeling cyclical casting processes in permanent molds and dies.

The die casting process mode can provide information about the following: —i The temperature distribution within the casting and die

sections at any time —i The number of cycles needed to reach a stationary

thermal balance during preheating of dies from room or preheat temperatures, the associated change in casting quality can also be observed

—i Optimal casting removal time (for a desired removal temperature)

—i Temperature variation at a given point over a number of cycles by the placement of 'virtual' thermocouples

—i Thermal loading of cores and dies and the effects of die cooling or heating on the die and casting

Page 7: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

OPTIMIZED REALITY

Assessment of critical temperatures in cores

The die casting process mode supports the following objectives: —i Optimal production conditions for permanent mold

and die casting processes —10ptimal layout of dies, including cooling and heating

lines —i Minimization of cycle times by the identification of

the earliest casting ejection time —i Assessing the thermal balance in the die —i Pinpointing areas in the die where thermal loading

is critical and could reduce die life —i Achievement of constant casting quality —i Investigation of the effect of interruptions during

production on casting quality

Assessment of the thermal balance of the die, also during breaks in production

POSTPROCESSOR PERSPECTIVE FOR VISUALIZATION AND RESULT EVALUATION

The result perspective allows the user to view the results on the real casting or mold/die geometry from any direc­tion and to slice through regions to identify critical areas. Temperatures in casting and mold can be viewed at any stage of the process. Porosity levels, the filling pattern as well as the thermal history can be viewed and evaluated as X-ray animations. Various criteria help the user to con­dense the information from filling, solidification or feeding into one comprehensive picture. Cooling curves and velo­city or pressure plots can be shown for any location.

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X-ray imaging allows insight into the flow pattern

Cooling curves, local flow velocities and pressures can be extracted and visualized for any point after the simu­lation. Results can be displayed in different views simul­taneously. Interactive and automatic rotation, clipping/ slicing, zooming and panning along the main axes and for a defined angle is possible. Results can be evaluated automatically as image sequences or movies.

Interactive views and slices through the geometry

Page 8: i Casting design and engineering - · PDF fileCOMPLETE SOLUTION FOR PROFITABLE HIGH QUALITY CASTINGS -i Casting design and engineering -i Gating and risering -i Reliable tool and patternmaking

OPTIMIZED REALITY

The result perspective offers the creation of user specific The MAGMA5 standard configuration includes all of the results or criteria. The visualization of the geometry and functionality described above. MAGMA5 can easily be results in 3D (virtual reality) is in preparation. linked to add-on modules for special processes, materials

or quality problems. Interfaces are available which allow

H :'{ U s e r R e s u l t s O r d e r Definit ion

Define the expressions to calculate results.

• Show Expression Column

Add Result Name Active Description

Von MAGMA Times 2006/01 SDAS = A_0 * t _ f - B

fur AISi7Mg: A 0=11 03 und B=0.33 t_f= Lokale Erstarrungszert

SDAS „ Scalar3D H

Von MAGMA Times 2006/01 SDAS = A_0 * t _ f - B

fur AISi7Mg: A 0=11 03 und B=0.33 t_f= Lokale Erstarrungszert

Von MAGMA Times 2006/01 SDAS = A_0 * t _ f - B

fur AISi7Mg: A 0=11 03 und B=0.33 t_f= Lokale Erstarrungszert

Clear Von MAGMA Times 2006/1:

M o d i f i z i e r t e s L e e LEE ~ G*t"(2/3t/V_s — 0 33*(G"2n-(2/3)/R ) - ( -0.29)

S<alar3D ^ G: Gradient R; Abkuhlgeschwindigfceit V_s: Wachstumsgescfiwtndigkeit der Erstarrungsfront mit V_s = R/G

G: Gradient R; Abkuhlgeschwindigfceit V_s: Wachstumsgescfiwtndigkeit der Erstarrungsfront mit V_s = R/G

Import

Export

( Cancel j j OK ] j

the export of results for use in other analysis programs.

MAGMA5 is compatible with appropriate commonly available hardware running 64-bit Windows 7 or Linux operating systems. MAGMA5 can be used on multi­processor, multi-core computers as well as on massively parallel cluster computers.

Definition and calculation of user defined criteria

DATABASE MODULE FOR MANAGING THERMOPHYSICAL DATA

The MAGMAdata module provides the user with the thermophysical material properties required for simula­tion. The user has the option to add or make changes to thermophysical data sets for different alloy compositions or materials. Process conditions can also be stored as required.

Additional databases for sleeves, filters or machine para­meters are also available. The database is divided into four differing areas of access..

www.magmasoft.com www.magmasoft.de

Subject to changes without notice. MAGMA and MAGMASOFT® are registered trademarks of MAGMA GmbH