Here, the engineers from Ferromatrix relied on the use of MAGMAstress, the MAGMASOFTR module for prediction of casting residual stresses and distortion. A first simulation showed that the originally selected casting layout caused a strong vertical distortion of the sub-ruler.
A reduction of the distortion of the subruler based on design changes to the component was not possible due to the available design space in the loom. Therefore, the foundry professionals from Ferromatrix were faced with the challenge of designing an alternative casting layout, which would lead to a lower level of distortion but still would maintain a quiescent mold filling and a porosity-free casting. This is a conflict which often occurs in the foundry: the large heat input caused naturally by the required feeder leads to large temperature gradients necessary to maintain a directional solidification. However, a minimization of casting distortion requires a homogeneous cooling of the casting associated with a reduction in temperature gradients.
With the help of the integrated simulation of mold filling, solidification and casting stresses, a casting layout was developed which resulted in casting distortion within the allowed tolerances, without compromising the other component requirements.
The same procedure has been applied successfully for the other castings in the new loom. Through the use of casting process simulation, Ferromatrix succeeded in realizing robust casting layouts for its structural components right the first time - without any need for long and expensive trial-and-error iterations.