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Computer simulation tools have become widely accepted in the metalcasting industry. Here is an update of some of the latest technology.
In recent years the application of computer simulation tools has become widely accepted within the foundry industry. The use of casting simulation has been extremely beneficial. It helps metalcasters avoid shrinkage and porosity problems, improves cast metal yield, and optimizes tooling design for diecasting processes.
However, the continuing development of these tools has been and is still on going in all fields, providing new and improved modules for many casting processes. A new micro model now allows the accurate prediction of the nodule count in ductile irons. A dedicated steel casting module incorporates the simulation of segregation and the heat treatment process, which can predict the final microstructures and properties in steels. With the aid of a newly developed stress module, the foundryman can predict residual stresses and distortion in both castings and dies.
The paper gives an up-date review of the new tools and modules in Magmasoft, which are now available to the foundry community to optimize their castings and production processes. New Software Features
New features have also been added to optimize postprocessing. Figs. 1.a to 1.d show a cam cover produced in high pressure die casting. The filling sequence is depicted by tracer-particles. Before the simulation is started the user selects a point from which Magmasoft, from Magma Foundry Technologies Inc., Arlington Hts., IL, releases `tracer particles' at regular intervals. The result can be animated as a transparent image showing the flow path of the metal entering the die or mold. Features such as eddies, turbulent flow and air entrapment are then easily identified.
Another new function is called the 'Xray' mode, which allows the user to show the results as an X-ray type image. During filling, only the metal cells which are completely or partially filled with liquid are shown. During solidification metal cells, which are completely solidified, can be displayed as transparent. This technique offers easy tracking of the different feeding paths in the casting during solidification.
Figs. 2.a-2.d show the solidification sequence in a high pressure die cast transmission case. Using the 'Xray' mode it is obvious that the upper section in the casting can not...