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.
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.
Real prototype – realistic casting?
Before start of production, many real castings are required for testing under realistic conditions. As with many of these prototype castings, the aluminum steering knuckle shown here was produced as a sand casting – a suitable process for low volume castings. The finite element analysis and durability calculations for a cyclic loading ...
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...
Everything counts – stresses from each manufacturing step
Using knowledge about thermally induced casting stresses in design and manufacturing is gaining acceptance in industry. These stresses are the root cause of many quality issues in castings, such as distortion, cracking, or reduced lifetime during operation.
- 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
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