Real-World Application of Core Simulation for Process Optimization

Jörg C. Sturm and Ingo Wagner
MAGMA Gießereitechnologie GmbH, Aachen, Germany

The making of cores still creates surprises for tool and corebox makers. Core related defects are a significant cost factor of casting production. The layout of coreboxes traditionally follows an experienced-based trial and error process until a satisfactory core quality is achieved. The ramp-up of new tools for production usually requires several time and cost intensive optimization loops, including the final approval under production conditions. Each trial run leads to more or less extensive tool changes, without the assurance for the foundry engineer that the chosen modifications actually lead to the desired success. Only the end-result is seen, so decisions are not based on a clear cause-effect-principle, which would confirm which change causes what effect.



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