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.

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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.

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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.

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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. The failure of the prototype casting in a test run would lead to design changes: heavier cross-sections to better withstand the load.

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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.

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Solving Casting Surface Defects

The surface of a die casting suffered from peeling or had two-tone discolorations. Sometimes a second buffing was required to eliminate these surface problems.

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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.

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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.

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Keeping Thin-Walled Castings Straight

Through the production of complex, thin-walled structural castings in light alloys, the foundry industry has been in a position to substitute castings for components that were classically sheet metal fabrications. These structural parts are characterized, in addition to their geometric complexity, by the requirements on strength and ductility they must fulfill.

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Washing Die Lube Problems Away

A throttle body produced on a dual-cavity die showed large porosities in a boss but “only“ in half of the castings. The size and color of the defects led to the conclusion that this was caused by die lube trapped on the bottom of the boss of one of the two cavities.

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