Case Studies
The following examples demonstrate how our customers successfully exploit MAGMASOFT® in order to realize better casting quality, cost savings or reduction of development times.
Going with the flow and fighting for air
Estimates say that 20 % of the costs of producing steel castings can be traced to inclusion removal and weld repair. Reoxidation inclusions, which form through melt contact with the air during pouring, make up a majority of steel casting inclusions.
Optimization saves launch of new miter saw
First die trials of a miter saw component produced visually sound castings and the results at the start of production were promising. This changed quickly during machining of the first parts delivered. Small amounts of air were entrapped and tiny porosities could be seen after machining. Having the die built and the design set, the die caster di...
Trying to get by without a riser
Stator housings are produced at the ITT foundry in Emmaboda, Sweden. In one housing, shrinkage porosity occurred at the top of the castings slightly below the surface. Because this area would be machined for a tightening ring, no porosity could be allowed.
Optimization of the cooling of a die
The layout of the tempering system for a high pressure die cast transmission case was performed using experience gained from other similar castings. Quality problems were experienced due to die temperatures that were too low.
Core and mold sand simulation
With increasing demands on casting quality and a tendency to thinner-walled structures for high performance components, the production of the corresponding cores has become a limiting factor for casting quality and productivity. The lifetime of a core can be investigated using simulation to optimize the process and core layout.
- Die casting
- Casting quality
- Cast component optimization
- Profitability and resource efficiency
- Casting design
- Automotive applications
- Heavy industries and wind power
- Permanent mold
- Cast iron
- Steel
- Nonferrous
- Core and mold
- Tool and pattern making
- Heat treatment
- Microstructure and properties
- Stresses and distortion
- no category
