Los siguientes ejemplos demuestran de qué manera nuestros clientes usan con éxito MAGMASOFT® con el fin de obtener una mejor calidad en la fundición, ahorrar costos y reducir tiempos de desarrollo.

Quality up, Costs down

Cold-chamber die casting is the preferred process for high volume production of light alloy castings. Currently, half of the world’s production is manufactured using this technology, while continuous improvements in quality are broadening its application for automotive components.

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Core and Mold Sand Simulation

With increasing demands on casting quality and a tendency to thinner-walled structures for high performance components, the production of the corresponding cores has become a limiting factor for casting quality and productivity. The lifetime of a core can be investigated using simulation to optimize the process and core layout.

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Riser Redesign to Feed Wheel Hub

Metalurgica Frum was trying to develop a wheel hub for several months without success. Despite these efforts, they could not avoid a shrinkage defect in a hot spot in the hub. They decided to stop tests on the shop floor and try a new central riser/sleeve design developed and verified using casting process simulation.

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Casting Distortions During Solution Treatment

Aluminum castings are often heat-treated to increase mechanical properties and simultaneously decrease thermal stresses induced by the casting process. The heat treatment process consists of 3 steps.

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Cold Laps in Cast Iron

DANA Spicer has used MAGMASOFT® to develop unconventional gating systems for ductile iron components for the heavy truck industry. In one case, they used simulation to check filling patterns and optimize the gating system of a ductile iron carrier. In production, the casting had a scrap rate of around 17%.

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Solving Casting Surface Defects

The wall thickness of this speaker housing was very thin at about 1.35 mm over most of the surface. There were several problems experienced in production. Blisters would occasionally develop on the exterior surface leading to casting rejection. Cold shuts formed in the side walls, and the filling was incomplete or had cold shuts on the top side.

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Fly Wheel Casting Simulation

Large cast iron castings require a high degree of attention in designing the layout, due to the high production costs and the limited number of castings produced.

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Analysis of Transmission Case Shrinkage Defects

In a high pressure die casting for a transmission case, a shrinkage defect was revealed after drilling of the boss. Due to the current die design, it was not possible to insert a pin into the die, making drilling of the boss the only option for this casting.

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New Markets for Casting

During recent years, the market for wind power has grown by orders of magnitude and has created a completely new sector for casting applications. Many of the components cast in this area today did not exist at all ten years ago or were created to substitute welded or forged parts.

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Extending Die Life by Eliminating Cavitation

The cover and ejector halves of a high pressure die casting die showed severe cavitation erosion. An evaluation of the filling process using MAGMASOFT® immediately showed an undesirable cavity filling pattern and extremely high gate velocities in combination with air pockets above and below the melt stream.

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