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.
When less is more
Producing large ductile iron axle housings can be a challenging task. The part shown above was well into production when a shrinkage defect was noticed during machining. After several attempts to find a solution, the foundry contacted MAGMA to evaluate the part design.
Problem corrected – case solved
An HPDC client in India who is a large manufacturer of motorcycles and scooters for both domestic and export markets, experienced porosity problems with a cast component from one of their suppliers after machining the casting on the top side.
Small changes result in big improvement
The original gating system of a front fork component led to problems that were analyzed using MAGMASOFT®. The original design of the gating system of the front fork led to several problems that were detected by simulation. The top ingate was filled too quickly, and this caused casting defects due to turbulence and a large amount of entra...
Keeping thin-walled castings straight
Through the production of complex, thin-walled structural castings in light alloys, the foundry industry has been in a position to substitute castings for components that were classically sheet metal fabrications. These structural parts are characterized, in addition to their geometric complexity, by the requirements on strength and ductilit...
Washing die lube problems away
A throttle body produced on a dual-cavity die showed large porosities in a boss but “only“ in half of the castings. The size and color of the defects led to the conclusion that this was caused by die lube trapped on the bottom of the boss of one of the two cavities.
- 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
