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Autonomous optimization of casting processes and layouts, shown here for gating optimization in die casting, is the future of casting processsimulation. MAGMA 5 5.2 introduces several new simulation capabilities: new process modes for permanent mold, low pressure sand and low pressure die casting, as well both hot-chamber and cold-chamber die casting, allow for detailed process-specific definitions. The software also supports process design by controlling process parameters during a simulation run. For gravity casters, process modules for DISAMATIC and investment casting are now available.

At GIFA, MAGMA will also present its newest developments for the quantitative prediction of as-cast and heat treated local microstructures and properties in aluminum, iron and steel castings. MAGMA 5 simulates sand and reoxidation inclusions during mold filling and predicts defects related to molding materials. MAGMAnonferrous calculates the final microstructure and mechanical properties for aluminum alloys considering the metallurgy, inoculation, and hydrogen content of the melt. MAGMAiron predicts local microstructures for iron materials from graphite growth through to the distribution of phases making up the matrix. MAGMAsteel calculates macrosegregation in steel castings and the local microstructure resulting from heat treatment. The stress module MAGMAstress for the first time offers casters the option to calculate thermally induced casting stresses in permanent molds for all manufacturing steps, including heat treatment and finishing, in order to predict casting crack problems and distortion. The simulated distortion results can be evaluated just as on a coordinate measuring machine and compared directly with real measurements.

For the first time, the new module MAGMAdielife facilitates the evaluation of the effects of tooling design and thermal stresses on the durability of permanent molds. MAGMA Core+Mold – transparency in core production. With MAGMA C+M, the simulation of the core shooting process is possible for complex tools, shown here for three cores including blow tubes in a single core box. With MAGMA C+M, MAGMA introduces an integrated tool for the simulation of core production processes. MAGMA C+M simulates core shooting, blowing and hardening of organic and inorganic cores.

Processes where binder hardening is driven by a catalyst gas as well as core production with tempered core boxes are supported. MAGMA C+M considers all aspects of core production starting from the core shooter, in order to calculate the flow of the air-sand mixture based on the real shot parameters. An integrated database provides the ability to specify the characteristics of the sand and the binder system as well as core box vents and blow tubes. The program simulates gassing, purging and the curing reaction of gas-hardened cores. The design and control of core box tempering for heat-cured cores (hotbox, croning, inorganic) is effectively supported by modeling of heating cartridges and oil channels.

For inorganic cores, MAGMA C+M calculates the drying of the core in the heated core box as well as due to transport of water vapor by hot air during gassing. MAGMA C+M takes advantage of all the functionality of MAGMA 5 and is available as an add-on module to MAGMA 5 or asa stand-alone product. Autonomous optimization is the future With autonomous optimization, foundrymen can make use of simulation in order to pursue their objectives for quality and cost. Autonomous optimization makes proposals for the right casting layout or the optimum process parameters. The virtual test foundry in the computer enables variation of parameters and systematic examination of influencing variables leading up to the optimum configuration. Based on the fundamental physics embedded in MAGMA 5, the program finds the best possible dimensions and positions of ingates, as well as the location of feeders and chills including their optimum size.

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