MAGMASOFT
DEVELOPED BY FOUNDRYMEN FOR FOUNDRYMEN
Our Tools Provide a Roadmap to Casting Quality and Optimization
MAGMASOFT® is a comprehensive simulation tool for the technological and quality focused production of castings worldwide. Our simulation capabilities show you the way by providing a better understanding of mold filling, solidification, mechanical properties, thermal stresses and distortions, and much more. Fully menu-driven with an integrated solid modeler, CAD interfaces, and extensive databases, MAGMASOFT® provides a complete solution for your design, production, and quality departments.
MAGMASOFT® helps you to avoid gating and feeding problems, predict casting quality, aids permanent mold design and reduces fettling costs.
PROCESSES
MAGMAhpdc
MAGMAhpdc provides a comprehensive simulation of the High-Pressure Die Casting (HPDC) process using detailed process and boundary conditions.
In MAGMAhdc all all important parameters influencing heat flow and the die thermal balance of the die can be considered, such as :
Ejection time
Die opening sequence
Delay time (simulating effect of cycle interruptions on the thermal balance)
Die closing sequence
Less time until the beginning of the next cycle
Individual control of each cooling or tempering channel
Definition of die spraying procedure
Venting and vacuum
Local squeezing definition
MAGMAhpdc also supports the setup of shot sequence by a comprehensive shot calculator module, considering the casting demands and the die casting machine capabilities. The shot calculator provides information for the simulation setup of the recommended first and second phase shot profile.
MAGMAlpdc
MAGMAlpdc is designed to perform a comprehensive process simulation for the low-pressure die casting process. MAGMAlpdc takes into account all process factors which affect the heat and fluid flow and casting quality.
MAGMAlpdc can provide information about the following:
The die filling based on furnace pressure
The feeding conditions in the casting during solidification taking into account the applied pressure and resultant metallostatic pressure and gravity
The effect of individual cooling or heating channels as well as their control
The effect of die spraying or coatings
The influence of cores or inserts
The effect of the sequence of die opening and closing through the individual control of each die section
MAGMAloastfoam
With MAGMAlostfoam an additional process module has been realized, which concentrates on the special physics during filling into the lost foam pattern. The module is based on a long term industrial research project for iron and steel and offers a unique approach to incorporate the degradation of the pattern, the counter pressure in the gap and the venting through the coating into the mold. MAGMAlostfoam amend the MAGMASOFT® product family since the release MAGMASOFT® 4.2 and can be used in the standard version for steel and aluminum projects. The graphite precipitation in cast iron can also be taken into account by coupling MAGMAlostfoam with MAGMAiron. So the module could also be used for cast iron machine tools as used in the automotive industry.
MAGMAwheel
MAGMAwheel is designed to perform a comprehensive process simulation of the low-pressure die casting process for wheel castings. The module takes into account any major heat and fluid flow relevant process and boundary condition. The functional range of the module MAGMAwheel corresponds essentially with that of the module MAGMAlpdc.
Main objectives of the module:
Definition of filling condition either as function of furnace pressure or applied at the gate, as function of time or flow rate.
Separate definition of pressures for filling within the tube and within the casting.
Definition of applied pressure time during solidification
Calculation of feeding conditions within the casting as function of gravity, the applied pressure and the actual metallostatic pressure.
MAGMAdisa
MAGMAdisa is a MAGMASOFT® add-on module and is an efficient tool for the analysis of the DISAMATIC® molding process. Using this process a flask less,
vertically parted mold is produced. The DISAMATIC® -process is designed to
produce cast parts of high quality with high productivity. The MAGMAdisa
module permits foundry engineers to include the important characteristics of
the DISAMATIC® process into simulation.
Using the MAGMAdisa module you can determine the following parameters:
maximum production rate
conveyor length
cooling time of the casting in the mold
or shake-out temperature
The process module MAGMAdisa has been developed together with DISA Industries and DaimlerChrysler. The MAGMAdisa module considers all substantial thermal
measured variables within the DISAMATIC® process cycle. The MAGMASOFT® data
base supports the relevant machine conditions for different DISAMATIC®
molding lines, as well as for casting systems recommended by DISA Industries.
MAGMArotacaster
The MAGMArotacaster module allows to simulate the dedicated process requirements of the rotacaster process during filling and solidification.
The rotacaster process allows to rotate the entire mold including an attached basin for the melt. The entire system is pressurized during solidification to support feeding into the casting and improve yield. Using MAGMArotacaster a given amount of melt is moved by rotation into the cavity and pressurization can be applied at a certain time during solidification.
OPTIMIZATION
Twenty years after the introduction of simulation software for foundries into the industry, a new era of simulation capabilities is dawning: Integrating optimization tools into MAGMASOFT® allow the optimization of casting designs or processes automatically. The foundry man defines his optimization goals and can evaluate the best possible solution.
MAGMA follows different routes to support optimization work of foundrymen: Empirical casting know-how is implemented into the set-up of casting and process design.
Using rigid optimization tools based on genetic algorithms the simulation tool automatically investigates different design or process alternatives, simulating the daily work of foundrymen to find the best compromise for a given casting problem.
MAGMAfrontier
The MAGMAfrontier module couples allows autonoumous optimization by integrating so called genetic algorithms, which basically “simulate” nature using decision mechanisms like “selection”, “elitism” and “mutation”. This allows casting process simulation to move to automatic optimization schemes.
MAGMAfrontier starts with the simulation of a suite of different designs, which can mean different process conditions or even geometry layouts. For any of these individuals a casting process simulation is completed. The software autonomously evaluates the results regarding the defined constraints and optimization targets. After that the software automatically creates a new generation following the genetic rules. Out of the total number of designs being defined and evaluated by MAGMAfrontier, usually several good designs are proposed and can be evaluated by the foundryman.
MAGMAfrontier currently supports the following objectives:
Feeder optimization
Optimization of gating and runner systems
Optimization of process conditions
Inverse optimization of boundary conditions and properties
Integration of Foseco Product Information
The MAGMASOFT® FOSECO Pro Module is a fully integrated database containing information about the geometries and properties of FOSECO feeding and filtration products. The MAGMASOFT® FOSECO Pro Module is designed to allow the user to directly import the geometry of FOSECO products from the database during creation of the rigging geometry. The database graphical user interface allows the fast and easy selection of the appropriate product for iron, steel or aluminum. The corresponding properties of these products are automatically defined and loaded from the database for the ensuing simulation.
INTEGRATION
The quality of a casting design is also judged by the ease with which it can be produced in large series. Increasingly, the advantages and requirements of the particular production process are being considered in part design. Casting simulation is applied to check feasibility, process window and final mechanical properties to be expected.
Casting simulation is a perfect platform for communication between designer and foundryman. There is no better way to document what really happens in the mold, than through casting simulation.
Interfaces
Interfaces - tools to fully integrate MAGMASOFT® into the design process chain of developing cast products.
MAGMAstl:
Using existing CAD data MAGMAlink:
Export of MAGMASOFT® Results into the world of designers
MAGMASOFT API:
Software library to integrate MAGMASOFT® with other applications
MAGMAlink
MAGMAlink supports the integration of casting process simulation into the product development chain.
MAGMAlink enables the import of meshes from different FE-packages for performance analysis into the MAGMASOFT® preprocessor. The results of the MAGMASOFT® process simulation can be transferred to these meshes. The use of this module requires the installation of a MAGMASOFT® standard license.
MAGMAlink currently supports file formats from the following simulation tools:
ABAQUS
I-DEAS
PATRAN
ANSYS
PERMAS
FEMFAT (I-DEAS-Universal-file)
FALANCS (IDEAS-Universal-file)
MAGMAlink reads external meshes and stores them as MAGMASOFT® geometry files (*. geo file) within the MAGMASOFT® preprocessor. These meshes can be combined with other CAD data or with geometries created with the MAGMASOFT® preprocessor. Additionally, MAGMAlink considers local co-ordinate systems during import and export.
Furthermore, MAGMAlink supports the conversion of MAGMASOFT® results into the file formats named above. In general, all MAGMASOFT® results can be converted.
Virtual Reality
Simulation produces millions of numbers. To create information out of this flood of data, the results have to be visualized. Modern result visualization delivers more than just pretty pictures - it must be possible to intuitively understand the calculated results. The information needs to be prepared and compressed by the software. Castings are three-dimensional and these dimensions can be made touchable already today using "virtual reality"ť. The animation of the casting process delivers the fourth dimension - time.
PROPERTIES
Perfect casting properties are the essence of high integrity cast components. Simulating casting performance is the key objective of MAGMASOFT®. This means to address the various aspects of physics, chemistry and metallurgy but also post-casting treatments.
MAGMAstress
The MAGMAstress module is a simulation software program for calculation of thermo-elastic / thermo-plastic stresses and residual stresses and strains in real three dimensional components. The program determines the stress distribution and related strains and displacements during the solidification and further cooling of castings. Additionally, stresses and strains within permanent molds can be evaluated for the entire process.
MAGMAstress allows:
determination of residual stress distribution of castings at room temperature
deformation and shrinkage of components
stress level formation and change as function of cooling conditions
the consideration of casting shake out for permanent molds and sand molds including removal of cores
stress related optimization of components geometry
stress related optimization of permanent molds and process conditions for improved mold and die life
determination of quenching conditions on stress and distortion level
MAGMAiron From Metallurgy to Casting Properties
Cast Iron quality is determined decisively by the applied melting practice, metal treatment and metallurgy. The prediction of feeding and structure formation of cast irons requires an accurate consideration of the microscopic phase separation, the foundries actual melt analysis and the type and effect of melt inoculation. The MAGMAiron module uses a microscopic kinetic growth model, which predicts the solidification sequence of cast iron alloys. Based on the alloy composition and the applied metallurgy MAGMAiron predicts the type and amount of graphite (grey, ductile or compacted iron) formed and gives an accurate simulation of competing graphite expansion and solidification contraction forces through which shrinkage and porosity are determined. This also allows the prediction of the final microstructures and mechanical properties in the casting.
MAGMAiron supports the foundryman by:
determining the effect of any risering and gating system design on the casting quality
removal or adjustment of features such as chill
provides "maps" for the variation in mechanical properties through out the casting
supports improved inoculation treatment in relation to alloy composition
MAGMAsteel - the path to sound and profitable steel castings
The MAGMAsteel module provides extended capabilities to support the entire manufacturing route for steel castings, from layout through heat treatment, production planning and methoding.
Convection and Segregation
MAGMAsteel uses the latest models to calculate the velocities and pressures of the metal in both the liquid melt and mushy zone due to thermal and solutal natural convection. The effects of this flow on the thermal map in the solidifying casting are taken into account. The calculated velocities are also coupled with an advanced microsegregation model for the dendritic scale, to track the redistribution of the elements in the alloy and predict macrosegregation.
Heat Treatment
The heat treatment of a steel casting plays a deciding role in determining the final microstructure and mechanical properties of the cast part. MAGMAsteel calculates heat transfer during the heat treatment process based on the changing conditions during austenitization, quenching and tempering. The analysis provides a prediction of the local microstructures and mechanical properties throughout the casting.
The hot tear susceptibility of steel castings can also be simulated in combination with the MAGMAstress module. MAGMAsteel and MAGMAstress are add-on modules that require an existing installation of the standard MAGMASOFT® program.
MAGMAnon-ferrous
The integration of casting simulation into the design chain as well as growing demand in know-how about local properties resulted in the request of the industry to predict structure formation and casting properties for non-ferrous components. MAGMA develops comprehensive new capabilities to simulate phase formation and resulting properties of aluminum and magnesium alloys as a function of kinetic growth models, considering the alloy composition, metal treatment and local cooling conditions. This results in the capability to predict the amount and distribution of preferential and deteriorate phases and hence helps foundrymen to set up robust process conditions and designers to understand the impact of their designs on the performance of cast components.
DAS, phase distribution and local mechanical properties are results available to the user.
Additionally MAGMAnon-ferrous allows predicting micro and gasing porosity defects based on actual gas content in the melt.
Temperature distribution during heat treatment Heat Treatment
For many castings the heat treatment process is a decisive part to establish the required casting performance.
Steel casting
Most steel castings receive their structure and mechanical properties through a proper heat treatment. MAGMAsteel offers comprehensive functionality to predict the distribution of microstructures and related mechanical properties as a function of the composition, the conditions during solution treatment, quenching and annealing.
Cast Iron
Residual stresses play a growing role for the performance of cast iron components. MAGMA develops software tools to predict the stress relief as a function of the applied process conditions.
Aluminum Castings
Many non-ferrous high integrity components undergo a comprehensive heat treatment to establish the required strength or ductility. T6 treatment creates the required properties, but also imposes substantial residual stresses into the casting as a function of the quenching and annealing conditions. MAGMAstress allows predicting the casting stresses during heat treatment. New developments in micro modeling consider diffusion and phase formation as a function of the applied thermal process.
Hardware and Software Requirements
Hardware
- Although earlier it was often necessary to have expensive workstations to carry out intensive simulation, today many calculations can be completed using common PC's. Good PC’s are now standard hardware for casting simulation. Nonetheless, computers are never fast enough
- more and more physics is considered in the programs, the models become more and more complex, and the answers need to be there earlier and earlier. When simulation programs are parallelized, it is possible to take advantage of the extreme power of parallel computers. These “clusters” cost less than workstations used earlier. With the appropriate software installed on a cluster, “experimentation on the monitor” or automatic optimization becomes reality.
Software
- Finally, the foundry man needs a trustworthy simulation program, which is continuously tested, maintained and improved.
Please contact MAGMA or its Partners for detailed information.
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