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 beyond just finding the shrink...
It is not just shrinkage that determines the final quality of a steel casting. Casting process simulation of steel castings also goes much further than just finding the shrink. In the case shown here, initially the gating and risering was developed for a drive tumbler that produced a high quality part, but the customer’s main interest was ...
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.
Head block distortion
Many large steel castings are produced with large machining allowances, which directly results in higher production costs. One reason for including this overstock material is uncertainty regarding the non-uniform distortion of the casting during solidification and cooling. Looking to reduce costs, Dedini Foundry used simulation to predict d...
Squeezing more out of a highly developed process
The production of ingots used to provide billets for many forging operations is a highly evolved process. However, it is very difficult to find additional improvements to maximize the useable volume of the ingot. The goal is to minimize the areas affected by shrinkage defects and to avoid segregation, as it leads to inhomogeneous material p...
Slag defects in plates
Steel foundries producing large components often pay more attention to the solidification process and less to the gating and the filling pattern of the casting.
- 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
