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.
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...
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.
Getting it right the first time
Risering of castings is supported through the determination of the local thermal modulus. This modulus describes the relationship between the heat content of a volume and the cooling power of the surrounding surfaces. For example, the hot spot with the largest thermal modulus (in this case 1.13 cm) must be fed by a riser with a higher modulu...
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.
- 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
