MAGMA5 – fully optimize: Latest Software Release offers fully integrated Optimization Capability for Casting Processes

Aachen, Germany, August 2015. MAGMA GmbH, based in Aachen, Germany, presents MAGMA5 Rel. 5.3, the next generation of simulation software for process optimization of all casting applications. The new version offers fully integrated capabilities for virtual design of experiment analysis and automatic optimization, and includes extended capabilities for all casting processes.

Optimization of casting quality and profitability with MAGMA5 Optimization of casting quality and profitability with MAGMA5

MAGMA5 - Metalcasting. Understanding. Robustness. Profitability.

 

For the first time, MAGMA5 Release 5.3 makes virtual experimentation and automatic optimization on-screen possible. Robust process conditions and optimized solutions for casting layouts and part production can be determined before the first casting is produced, offering substantial cost saving potential. The software is designed to find the best possible set-up for runner dimensions, gate positions, and also for both the position and the optimum size of feeders and chills, within given ranges. This enables foundrymen to use simulations in a virtual proving ground to pursue different quality and cost objectives simultaneously.

Quantitative assessment of different steel casting gating systems, here evaluating re-oxidation inclusions in the casting Quantitative assessment of different steel casting gating systems, here evaluating re-oxidation inclusions in the casting

To support this new methodology, comprehensive capabilities for the automatic variation of geometries by means of parametric design have been created. Furthermore, special statistical tools for design of experiment analyses and genetic algorithms for process optimization were added to MAGMA5. A new Assessment Perspective allows a fast and easy quantitative comparison of numerous simulation results. Correlations between geometrical and process variables, quality criteria, and objectives are concisely summarized and clearly visualized. Predefined settings and the automation of both calculations and result evaluation make working with MAGMA5 even more effective and efficient.

Parametric design of a die casting runner systemParametric design of a die casting runner system

Virtual experimentation and optimization are thus fully integrated into MAGMA5 for the first time. Regardless of whether the foundry specialist simulates an individual project or whether a virtual design of experiments or a comprehensive optimization is carried out: MAGMA5 offers an entirely new methodology as well as powerful tools to deepen the understanding of the process, determine robust process conditions, and find optimized solutions for casting layouts and process parameters before the first casting is produced.

 

MAGMA5 - Casting Fascination

 

Additionally, MAGMA5 Rel. 5.3 offers various new developments for a precise investigation of different casting processes as well as for a quantitative prediction of as-cast and heat treated casting properties. For cast iron alloys, the prediction of the ferrite/perlite-ratio, the calculation of the eutectic temperature, as well as the model for white solidification, were further improved. A significant step forward is the modelling of the heat treatment in the production of ADI (austempered ductile iron). The module MAGMAsteel now predicts sand and re-oxidation inclusions during filling, including their movement due to convective flows during solidification. The MAGMAnonferrous module offers new criteria for local solidification and feeding conditions and an improved prediction of the dendrite arm spacing.

 

The definition of the mold filling conditions in gravity casting processes is now supported by settings for the automatic filling control of the pouring basin. A target fill level can be set, and the software automatically matches the pouring rate accordingly. The tracking of enclosed air during mold filling has been greatly improved. Foundrymen casting large parts will benefit from the improved ladle assistant, now supporting parallel as well as sequential and discontinuous pouring from several ladles.

Automatic control of the metal level in the pouring basinAutomatic control of the metal level in the pouring basin

A new and computationally efficient radiation model can be used to consider different radiation conditions and shadowing effects in the heat transfer for investment and ingot casting processes.

 

For all sand casting processes, an improved transport model for water in the molding sand was integrated. This allows a more exact consideration of cooling requirements especially for the green sand. The user can now access extended data in the FOSECO Pro Module, as well as the new riser databases of ASK Chemicals and Chemex.

 

The stress module MAGMAstress is designed to identify thermally induced stresses in castings and permanent molds for all process steps, including heat treatment and machining, in order to predict crack problems and distortion. Creep effects in the cast material during cooling and heat treatment are considered. Improvements in the measurement perspective allow an easier comparison of predicted and measured distortion. Supporting new file formats and bringing numerous other improvements, MAGMAlink is now completely integrated into MAGMA5.

 

MAGMA C+M - Transparency in Core Production

 

In the new MAGMA C+M version, numerous options to predict and optimize core production processes are now available. MAGMA C+M allows simulation of core shooting, gassing and hardening of organic and inorganic cores. For the optimized layout of core boxes and production processes, MAGMA C+M makes new criteria available to evaluate both the core shooting and gassing processes, and to predict core box wear. In addition, air and sand flows are now visualized effectively by means of tracer particles.

Prediction of flow behavior during core shooting: sand tracer (left) and air tracer (right) Prediction of flow behavior during core shooting: sand tracer (left) and air tracer (right)

Efficient Work with New Tools

 

A new local job queue in MAGMA5, and the possibility to generate image sequences automatically and in parallel, supports work and resource planning as well as virtual experimentation and optimization efficiently.

 

The new Assessment Perspective allows an easy and quick quantitative comparison of numerous simulation results. In combination with the Result Perspective, an efficient examination of robust process conditions and optimum solutions for different quality criteria is now possible. Both perspectives are coupled: for each working point of a virtual trial, the corresponding 3D results are directly accessible.

 

The available tools show all results of individual simulations combined as comprehensive quantitative values in tables or diagrams. Correlations between design and process variables, quality criteria and objectives are swiftly and clearly visualized. The main result table, sorted bar chart, scatter chart and parallel coordinates diagram are among the most important tools for this purpose. Significant cause-effect relationships can be evaluated graphically through main effect diagrams, correlations matrix and curve comparisons.

Concrete measures for improvement shown in the parallel coordinate diagram Concrete measures for improvement shown in the parallel coordinate diagram
Scatter chart for analysis of different inoculation conditionsScatter chart for analysis of different inoculation conditions
Correlation matrix summarizing interaction of variables and quality criteriaCorrelation matrix summarizing interaction of variables and quality criteria
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