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.
Engine blocks full of stress
Cast iron engine blocks can be found in more than half of all passenger cars. Their performance and weight are, among other criteria, dependent on their geometry and the casting process, especially defects like porosity and residual stresses.
Two for one
The productivity of the casting of a cover was to be improved. Originally, the part was produced using a single cavity die and fulfilled all quality requirements. To increase productivity, a change to a twocavity die was wanted, without making any compromises regarding casting quality.
Shortening cycle times in cylinder head production
In the development of a high performance, economical engine, a cylinder head design was required that would withstand the higher combustion pressures. The existing design of this part led to long cycle times. It was necessary to reduce solidification times without compromising the casting performance in order to reduce the cost per head. One opt...
- 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
