MAGMA5 - optimized reality

Second version of new software generation for casting process simulation released

Aachen, June 2011. With MAGMA5 Release 5.1, MAGMA GmbH introduces the next generation of its new software for casting process simulation. MAGMA5 5.1 addresses all casting processes and continues the series of MAGMASOFT® solutions used by foundries world-wide for optimizing cast component production.

MAGMA5 provides numerous new simulation capabilities including: new process modes for permanent mold, low pressure sand and low pressure die casting as well as die casting (for both hot-chamber and cold-chamber processes) allow detailed process-specific definitions. At the same time, the software aids in process design through the control of relevant process parameters during simulation, for instance, for heating or cooling of the die and for the optimization of cycle times. Gravity casters already using MAGMA5 can now also apply specific process modules for DISAMATIC and investment casting.

MAGMA5 allows the easy import of geometry via interfaces as well as the interactive creation of geometry. The screenshot shows the cast component’s geometry from which the die halves, slides and cores can be derived for manufacturing (shown in an exploded view, left image). MAGMA 5 version 5.1 provides an interactive or automated evaluation of results also for die and permanent mold castings. The results can be zoomed, rotated or panned (images middle and right).

The software provides the prediction of sand inclusions and in steel castings simulates reoxidation inclusions based on turbulent mold filling. New capabilities for the prediction of microporosity complement the existing feeding prediction during solidification. Moreover, a new module for the simulation of as-cast local microstructures and properties of aluminum alloy castings in sand and permanent molds is available with MAGMAnonferrous.

The module MAGMAstress has been completely reworked and for the first time offers the option to simulate thermally induced casting stresses in permanent molds for all manufacturing steps. A comprehensive plasticity model provides improved accuracy, as it considers both temperature-dependent as well as time-dependent effects on stresses and distortion. Newest contact algorithms allow the analysis of cracking problems and distortion also during cooling in the die.

The assessment of predicted casting distortion is made easier using new result evaluation and visualization tools in the result perspective. The simulated distortion can now be evaluated similar to a coordinate measuring machine and compared directly with real measurements.

The new module MAGMAdielife supports the evaluation of the effects of die design and thermal stresses on tooling durability in permanent molds.

New interfaces in the module MAGMAlink provide further options for data exchange with other computational analysis programs.

The new MAGMA5 module MAGMAnonferrous provides the quantitative prediction of microstructures and properties of aluminum alloys

Integrated information and tools for simulation projects

In MAGMA5, all of the necessary steps for casting process simulation can be specified from a process perspective. Following the manufacturing process, the user is automatically guided through the program. The complete production process from casting design, gating and risering or die layout, through to casting and finishing processes such as heat treatment, can be described and simulated. In the process perspective, all information about the used materials, metallurgy and melting practice, production conditions and finishing processes come together. This also includes information regarding the removal of the casting rigging, heat treatment or finishing of the cast component. The user always has a complete overview of the entire manufacturing process he wants to simulate.

Taken together, the process orientation of MAGMA5 sets the basis for a profitable manufacture of cast components – through optimized casting layouts and processing conditions, preventative quality assurance, and cost effectiveness.

Prediction of tool durability with the new module MAGMAdielife

MAGMA5 in a compact overview:

  • Comprehensive project management
  • Solid modeling with a CAD kernel as well as import and export of CAD data (STL, STEP, CATIA, Pro/E)
  • Automatic enmeshment of the geometry within seconds
  • Comprehensive process description for all casting processes, with direct access to all process steps and the related simulation definitions via the process perspective
  • Specific process modes for sand casting, permanent mold, die casting (hot-chamber and cold-chamber), low pressure sand and low pressure permanent mold casting, DISAMATIC and investment casting
  • Completely new capabilities for the prediction of: mold filling, microporosity, inclusions, feeding related porosities, prediction of local microstructures and properties for iron, steel, and aluminum-alloys, sand-related defects, thermal stresses and distortion of the cast component and the tooling for all production stepsSimulation of heat treatment and machining of cast components
  • Interactive and automated result evaluation
  • Comprehensive database for all required data and properties for casting processes and materials
  • Optimized for the parallelized use of multi-core hardware
  • Available for 64-Bit Windows and Linux operating systems
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