Gases are generated during the casting process when the binder systems used in the cores and molding materials decompose. Prediction of Binder Decomposition and Core Gases In addition to the comprehensive toolbox for high pressure die casting, MAGMASOFT® 5.4 offers numerous other new capabilities for casting optimization and process validation. Why Engineering Simulation is Becoming Increasingly Important Casting Optimization Beyond High Pressure Die Casting New quality criteria like the local porefree zone thickness help to securely design die cast components by taking into account the casting properties. Therefore, minimization of casting distortion through the optimization of production parameters, or by compensating for dimensional change when designing the die cavity, or through the design of heat treatment racks can be investigated during the development process (Fig. The simulation of heat treatment is also seamlessly integrated.
With the integration of all important process steps in die casting, the virtual process chain is represented realistically: from ejection, quenching and cooling of the casting, through trimming of gates and overflows, to consideration of the residual stress redistribution caused by machining of the as-cast part.ĭie casting tool design is supported by the calculation of contact pressures between casting and die, now including the prediction of the corresponding required ejector forces (Fig. Market Review The Indian Aluminium High Pressure Die Casting Industry MAGMASOFT® 5.4 now additionally offers an intuitive visualization for all casting processes of the thermal balance between the casting and the die for the quantitative evaluation of energy exchange over the complete process, in individual process phases, or for defined time intervals (Fig. The flow within cooling lines, spot cooling or conformal cooling near the die contour can be optimized for increased thermal efficiency, by taking into account the cooling medium with its inlet/ outlet conditions, temperatures, and flow rates (Fig. This enables an even more precise evaluation of the influence of spraying on the thermal balance in the tooling, the distortion of casting and die components, or local die lifetime (Fig. Magmasoft Optimizes Autonomous Engineering Die Casting Simulation of the Spraying Processīased on the level of detail required to achieve a given objective, MAGMASOFT® 5.4 offers various capabilities for optimizing the spraying process in both die casting tooling and process development: a classical approach with uniform heat extraction from the cavity in early-stage product optimization, an extended approach with user-defined static or movable spray areas, or even the realistic consideration of the spray head with individual circuits, nozzle positions, and programming of the head movement. The consideration of the available machine capacity (PQ2 diagram), the venting conditions and the complete thermal balance in the die, which are all critical for casting quality, can be evaluated at the earliest stages of process and tooling design.
This enables the optimization of dosing parameters, dwell times, plunger velocities, and switching points.
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With these new features, the software enables the detailed investigation of the dosing process and the shot profile considering the shot chamber geometry (Fig. The new solver can simultaneously calculate different flow models (such as the flow through cooling lines during filling of the casting) while also supporting flexible boundary conditions (plunger movement, squeezing).
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A new algorithm for the filling process in high pressure die casting considers the special requirements of the process on the description of the free surface of the melt, the metal viscosity, and the prediction of air entrapment for improved result quality. With the innovative TAG-meshing (True Adaptive Geometry), MAGMASOFT® 5.4 offers new possibilities for the flexible, local meshing of the geometry. Gallery with 10 images New Solver for High Pressure Die CastingĪ major advancement in the new version is the extensive support of the development for the component, the tooling and the process setup of high pressure die casting.
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