Product category:
Metals foundry, materials and equipment
News Release from: Magma | Subject: MAGMAfrontier casting process development
Edited by the Manufacturingtalk Editorial
Team on 26 April 2006
Module avoids casting process 'trial and
error'
A module is the first step towards a new generation of optimization software that supports the foundryman by proposing solutions regarding optimal process parameters or casting layouts.
MAGMAfrontier is the first step towards a new generation of optimization software that supports the foundryman by proposing solutions regarding optimal process parameters or casting layouts Instead of performing expensive 'trial-and-error' experiments, the results of filling, solidification, or stress simulations are used for optimization by producing a series of 'virtual castings' under different conditions
This article was originally published on Manufacturingtalk on 16 Aug 2004 at 8.00am (UK)
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MAGMASOFT is integrated into an optimization loop, which is executed automatically without user interaction once the goal and constraints of the optimization have been defined.
The variable parameters that have been selected are optimized using so called genetic algorithms.
The program analyzes various combinations of these parameters (so-called designs) in successive generations.
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MAGMAfrontier 'learns' from the previous results and in this way quickly reaches an optimal solution.
The process allows the analysis of various objectives simultaneously, even if they are at odds with one another.
This closely corresponds to the work of the foundryman who has to continuously find the right compromise between conflicting solutions in his day-to-day work.
* Automatic optimization facilitates the operating process - MAGMAfrontier supports the goal-oriented layout of gating and risering systems, so that there is no need for a large number of expensive trials.
Using parameterized geometries, the user can, for example, vary the type, number, and location of feeders on the casting.
In this way it is possible to concurrently follow the objectives of reaching a minimum of porosity and a maximum yield for a casting.
A number of other casting parameters can be optimized using MAGMAfrontier.
This includes, for example, the layout of the cross sections or the number of gates for an optimized filling process.
The best location for chills or cooling lines can also be analyzed.
Another important area that can be studied is the influence of the gating and risers on component distortion due to residual stresses that are generated during the cooling process.
In this case, MAGMAfrontier allows the optimization of the casting system, the feeding technique, and the gating design based on MAGMASOFT results.
The variation of process parameters with regard to casting quality is, of course, also possible.
* Assuring quality - optimization objectives can be formulated to find the relationship between production parameters and casting properties.
The pouring temperature or the shake-out time can be optimized to achieve the desired mechanical properties or the composition of an alloy can be adjusted to reach a given target.
Thermal loading in high pressure die casting tools can be minimized by optimizing the cooling, spraying, and ejection conditions, allowing an increase in productivity at the same time.
As the result of an optimization run, MAGMAfrontier often proposes solutions that the user would not normally consider.
The determination of optimal simulation parameters such as material properties or pouring conditions based on the comparison of measured and simulated data, so-called inverse optimization, is possible with MAGMAfrontier.
An example is the determination of the real cooling conditions during the quenching of aluminum cylinder heads for use in the simulation of residual stresses.
Additionally, MAGMAfrontier provides information on how modifications of the input values influence the optimization objectives.
In other words, the module shows the significance of the input values, indicating which are of primary importance and which play a secondary role.
This provides valuable information to the foundryman for process design.
MAGMAfrontier complements the technical knowledge of the engineer.
1 - optimization process with MAGMAfrontier.
Based on a selection of start designs with certain degrees of freedom and manufacturing limitations, the optimization algorithm analyses various objectives at the same time, in this example casting quality and returns.
2 - autonomous feeder optimization for the prevention of porosities.
(a) initial situation (b) optimized result.
3 - casting distortion before and after the optimization of runner designs.
Varying the web width of the runner between the individual feeders leads to different rigidities and shrinkage constraints of the component.
The distortion of the bend was significantly reduced after taking these measures.
4 - autonomous optimization of a runner in high pressure die casting.
MAGMAfrontier optimizes the geometry of the runner with the aim to reduce the amount of entrapped air during the filling process.
(a) bad design with areas of entrapped air (b) optimized geometry of the runner.
* About Magma - new view on casting process simulation and optimization - the demands on functionality and quality of castings and the productivity and reliability of the casting process are continuously increasing.
Since 1988, it has been the aim of Magma to provide a new view of the casting process with its casting process simulation tool MAGMASOFT, and thereby support optimization in all areas of the process chain from casting development to volume production.
Today, Magma in Aachen, Germany, is the leading partner for casting design and manufacturing industries.
More than 900 Magma customers worldwide prove that the challenges facing the casting process can only be successfully met when relevant knowledge, powerful software, and a competent support work hand in hand.
With more than 25 experienced foundry engineers and as many engineers from other disciplines, Magma provides a fast and effective engineering task force.
There are more than 100 employees of Magma at six locations: in Aachen (Germany), Chicago (USA), Sao Paulo (Brazil), Singapore, Seoul (Korea) and Hellebaek (Denmark).
Furthermore, Magma is represented by around 30 competent partners worldwide.
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