For Scherb, a crucial cornerstone to realizing this strategy is MAGMASOFT®. He has been employing the software, which he first came in contact with during his studies at RWTH Aachen University, for many years now. “With MAGMASOFT®, we started with a tool that had not yet been applied in many foundries and which now helps us in the analysis and the design of the complete ‘casting value chain’. This provides a valuable competitive edge in both the range of our offerings and the cost-effective production of high-quality castings”, Markus Scherb sums up the corporate benefits of MAGMASOFT®.
The connection between economical and technical benefits of casting process simulation with MAGMASOFT® can be clearly illustrated in a benefit pyramid: The constructive use of the software for the lay-out of tool-ing, gating and risering design and finally the control of the solidification process leads to optimum tooling and patterns. This, in turn, is the basis for high-quality cast components. The successive cost savings ultimately result in a higher profitability.
Scherb runs up to 300 simulations yearly leading to Euro savings running into five digits, as illustrated by the following selected examples:
Scherb saved roughly 12,000 Euros because they managed to correct the gating system of a tool during samp-ling before the start of production. Cost savings of 25,000 Euros were realized through the modification of a gating system, reducing metal velocities at the ingate in order to reduce mold wear and extend the tool’s lifetime. A cost reduction of 20,000 Euros was realized through reduced testing and inspection efforts, since the reconstruction of a die insert resulted in reduced pore formation. The reduction of cold flow problems by using a new ingate system saved another 11,000 Euros.
With roughly 100 different projects per year, it becomes obvious which crucial role casting process simulation has for the profitability of the foundry – without taking into account the increased revenue that Scherb realizes through new customers convinced by the argument “casting process simulation”.
„MAGMASOFT is a strategic investment for us because the software decisively improves our market position and economic situation”, sums up Markus Scherb with a view to the challenges outlined above. “With this we were able to establish ourselves as a partner for industries with sensitive and demanding cast components like gear boxes, thread guides for textile machines, components for pre-combustion chambers for heaters, and surgical microscopes”.
“Moreover, the software protects us from losing know-how, as now the knowledge is stored not only in an expert’s brain but is also saved so that it can always be re-used in the databases of MAGMASOFT”, confirms Markus Scherb.