MAGMA attaches great importance to intensive alliances with leading universities and research institutes and is actively involved in a number of national and international research projects.
MaBIFF: "Dimension-reduced component properties through the integration of production and functional simulation"
The aim of the research project MaBiFF was to assess the influence of different microstructural features in cast iron (GJS-400 and GJV-450), which can be locally predicted using casting process simulation, on durability. For this purpose, S-N curves were determined for varying microstructures from extensive tests, enabling the creation of a closed chain considering the manufacturing parameters through the calculated local microstructures up to a prediction of the local durability. This makes the transfer of the influence of the manufacturing process in operational fatigue calculations possible.
Within the scope of the MaBIFF project, the prediction of local microstructures was extended. For this purpose, MAGMA developed a calculation procedure in which process simulation was integrated into computational fatigue calculations. A correlation between the local durability and the local microstructure was determined. In addition, the necessary interfaces for data exchange with programs for fatigue life calculation (for example, FEMFAT, LMS Virtual Lab Durability) were created. This makes it possible to calculate the expected durability for the materials GJS-400 and GJV-450 based on a casting simulation and to transfer this information as input for durability calculations.
This research and development project was funded by the Federal Ministry of Education and Research (BMBF) under the funding code 01RI0713 and was supervised by the German Aerospace Center (DLR) in Bonn. The project was carried out as a joint project between 01.08.2077 and 31.03.2011.
Project partners in this project were Audi AG, Eisenwerk Brühl GmbH, Meuselwitz Guss GmbH and Walter Hundhausen GmbH, Fraunhofer Institute for Operational Strength and System Reliability LBF, Fraunhofer Institute for Technological and Economic Mathematics ITWM, Germanischer Lloyd Industrial Services GmbH, Institute of Foundry Technology IFG and MAGMA Gießereitechnologie GmbH .
A detailed project summary can be found here: Bundesministerium für Bildung und Forschung.
The Music Project was aimed at developing a “MUlti-layers control & cognitive System to drive metal and plastic production line for Injected Components“ under the EU Factory of the Future initiative, targeted at improving efficiency, adaptability and sustainability of manufacturing systems as well as their better integration within business processes in an increasingly globalized industrial context.
This ambitious and challenging goal can support High Pressure Die Casting and Plastic Injection Molding Companies in achieving lower scrap generation, higher efficiency and robustness, and minimize energy consumption.
The idea behind the project was to link the new Control and Cognitive system to real-time monitoring for an active quality control.
One objective of MAGMA in the project was to improve the quality prediction of the high pressure die castings with simulation. New criteria for the simulation were developed and validated with the help of a “horse shoe” test geometry. At the end, also real demonstrator components like a shock tower from the partner Audi were used to apply the generated know-how.
For such a Meta-model to be realized, numerous experimental data were generated, and MAGMA additionally added virtual experiments (DoE), with varying process parameters and their influence on the casting quality, to train the Meta-model before foundry trials started..
More information can be found on the project website: http://music.eucoord.com
In addition a booklet is available, which summarizes the main results of the project:
“Smart Control and Cognitive System applied to the HPDC Foundry 4.0”
Edited by Nicola Gramegna and Franco Bonollo, Assomet Servizi Srl, Enginsoft SpA
EffSAFound2– Energy and Material Efficiency in Iron and Steel Foundries
The German Federal Ministry of Education and Research (BMBF) supported CLIENT research initiative to improve energy and material efficiency in South African foundries "EffSAFound2" has been successfully completed. In the project, German and South African partners cooperated for 30 months together with eight South African steel and iron foundries.
Within the scope of the project, comprehensive material data for high-chrome white iron was measured and implemented in MAGMA5. To meet the demands for improved energy efficiency and use of resources in the foundries, reference examples based on current foundry projects were optimized using MAGMA5.
The transfer of knowledge and skills regarding foundry processes and machine operation is especially demanding in South Africa, due to eleven official languages and diverse employee qualifications. To better support this process, an English version of the software hg.visutec from HegerPro is now available. The provided multimedia content will help to raise the awareness of employees and to optimize work routines.
In addition, the management of sand in the foundries was successfully improved. A procedure was developed by the German company GUT Gießerei-Umwelt-Technik to check the organic components of waste sand and was adapted on-site. A central facility for modular thermal or mechanical sand regeneration is currently in development.
Within the project, Ametex, MAGMA’s South African partner, trained amongst others students in the use of MAGMASOFT® to improve casting quality in the participating foundries.
Efficient process chains for aluminum die casting
The aim of the joint project was to increase the utilization efficiency of energy and resources in the aluminum die casting process chain. The focus of the project was the overall process chain from melting the starting material through the actual casting process, an alloy-dependent heat treatment and machining to the product in the required final quality.
MAGMA has played a central role in the project, since the simulation of the die-casting process can be used to determine and verify decisive measures to increase the utilization efficiency of energy and resources. For this purpose, MAGMA systematically applied MAGMA’s process optimization capabilities in die casting. The focus of the investigations was the reduction of volume or return material, the minimization of the cycle times, the setting of an optimal spraying process and the increase of tooling life. For this purpose, heat transfer coefficients were also determined on a test stand.
The project was selected by independent experts as part of the BMBF framework "Research for the production of tomorrow" within the "innovation resource efficiency" of the ideas contest "Improving energy efficiency in production technology".
The project was carried out between 01.06.2009 and 31.08.2012.