MAGMASOFT® 6.1 – Engineering, Economics and Sustainability
MAGMA, a leading German developer and supplier of software for the simulation and optimization of casting designs and processes, introduces MAGMASOFT® 6.1, the latest version of its casting process simulation software. With extensive revisions and new functionalities, the software enhances the simulation of low pressure die casting processes, and expands the capabilities for die casters and users of MAGMA CC and MAGMA C+M. For the first time, MAGMASOFT® includes a dedicated process module for rheocasting and thixomolding. In addition, a new ECONOMICS perspective enables users to quantitatively assess costs and CO₂ emissions based on already defined geometry, material, and process data. These innovations provide faster, more precise results, promoting sustainable and economically optimized casting processes.
Innovation in Lightweight Design: MAGMAsemisolid
MAGMAsemisolid is a new process module for MAGMASOFT® that has been specifically designed for simulating semi-solid manufacturing processes such as rheocasting and thixomolding. These processes are particularly suitable for lightweight design applications with aluminum and magnesium alloys.
A specially developed viscosity model realistically replicates the thixotropic flow behavior of semi-solid metal suspensions, accounting for dependencies on shear rate, temperature, and time. This enables accurate simulations and comprehensive optimization of process parameters to produce components with higher quality and reduced scrap rates.
Detailed analyses of material distribution and solidification behavior support users in both developing new designs and refining existing processes. MAGMAsemisolid also offers an intuitive user interface that facilitates access to important simulation data. Results can be clearly visualized and exported for further analysis. In combination with other MAGMASOFT® modules (e.g., MAGMAstress), MAGMAsemisolid supports the continuous optimization of the entire manufacturing process.
MAGMA ECONOMICS: Focus on Sustainability and Profitability
MAGMA ECONOMICS is a new perspective in MAGMASOFT® that allows users to quantitatively evaluate both the economic and the ecological impact of process variants. By utilizing already defined geometry, material and process data along with simulation results, MAGMA ECONOMICS calculates and compares costs, energy consumption, and CO₂ emissions across different scenarios, enabling informed decision-making.
Customizable templates for common materials and processes incorporate specific cost and emission factors. This enables a detailed analysis of resource consumption and manufacturing costs throughout the entire casting process simulation chain – from mold or tool preparation, to the pouring process, and even potential machining.
With MAGMA ECONOMICS, users can vary process parameters individually and compare scenarios without investing additional simulation time. This capability facilitates informed decisions that align with both technical requirements and cost or resource objectives.
For example, a foundry can determine which design of a casting layout minimizes CO₂ emissions while maintaining product quality. MAGMA ECONOMICS automates the calculation of CO₂ balances and production costs, simplifying the optimization of both ecological and economic performance.
Fully integrated into the standard version of MAGMASOFT®, MAGMA ECONOMICS requires no additional modules or licenses, providing users with a powerful tool for developing more sustainable and economical processes.
With MAGMAsemisolid, MAGMASOFT® 6.1 extends its functionality with a powerful tool for semi-solid processing and helps users fully leverage these innovative manufacturing technologies.
Further Improvements and Enhancements
MAGMASOFT® 6.1 introduces a wide range of additional features and enhancements that make casting simulation even more efficient and precise.
The new "Virtual Gate" function in MAGMAhpdc enables die casters to position multiple inlets directly on the casting and reference the gating system to them. This allows for a quick initial assessment of the die filling process without explicitly defining the gating system, shot chamber, or shot parameters.
For users of MAGMAstress analyzing casting distortion, a new 'Geometric Dimensions' measurement mode has been introduced. This feature simplifies the evaluation process by enabling direct measurement of distances, flatness, and roundness during result assessment, considerably enhancing evaluation accuracy and ease of use.
The new 'Volume Wrap' function allows users to group several volumes into a geometric shell, significantly improving the display of results and supporting better analysis and more effective optimization of process parameters.
A new particle counting feature, available in all process modules and products, tracks selected tracer particles. For example, users can localize unwanted inclusions in the casting at an early stage. The results can be visualized over time and contribute to more effective quality assurance.
MAGMASOFT® 6.1 has been enhanced with automatic project export functionality, significantly reducing manual effort and making critical data more accessible for MAGMAinteract®, the stand-alone, free-of-charge application for visualizing MAGMASOFT® simulation results
With these extensive innovations, MAGMASOFT® 6.1 reaffirms MAGMA’s commitment to casting excellence, empowering users to achieve more efficient, precise, and sustainable manufacturing processes.
