Magma

Magma

Simulation and virtual optimization of casting processes

Magma

MAGMA is a product of MAGMA GmbH

MAGMASOFT® is the comprehensive and effective optimization tool for improving metalcasting quality, optimizing process conditions and reducing production costs. Consequently utilizing the methodology of virtual Design of Experiments and Autonomous Optimization, robust process parameters and optimized casting layouts can be established for all cast materials and processes including heat treatment and melt metallurgy – efficiently and comprehensively at the same time.

By means of Autonomous Engineering, simulations with MAGMASOFT can be used in an automated virtual test plan to pursue different quality and cost objectives simultaneously. Broad knowledge and tangible hands-on instructions/measures are generated considering design and process conditions for mold filling, solidification and cooling. The range of results comprises residual stresses and distortion, microstructure formation and local properties.

A modular software design covers the complete process chain of cast components. The software can be applied for optimized process robustness and part quality from conceptual to final component design, during the tooling layout and prototyping, all the way through to the production and heat treatment processes.

Magma - Simulation and virtual optimization of casting processes

Main benefits

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  Supports all cast materials and all aspects of casting manufacture

  A virtual test field for the reduction of metalcasting defects

  Identification of optimal process conditions for robust process windows early and reliably

  Faster decision making to establish saving time for all parties involved

  Improvement of quality management by generating systematic understanding how process variability affects quality

  Reliable and early information to designers for robust product and process development

Documentation

technical paper

Process Production Optimization of a Die-Casting Component for Automotive

This work describes as Tecnopress S.p.A., leader in die-casting components supply on a worldwide level, has applied the numerical optimization so to enhance the control on the production process of an automotive component, allowing to reachthe expected qualitative level without affecting the production cost.

Read the technical paper

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Insights

CASE STUDY

Comparative analysis of temperature control systems for high pressure die casting dies

Numerical methods for the thermal analysis of the HPDC process are needed to shorten the cost, the design and production time and the samples to involve in finding acceptable operating conditions.

In High Pressure Die Casting production it is necessary to keep the die temperature within a certain specified range

die-casting magma metal-process-simulation

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training courses

FOUNDRY PROCESSES course catalogue

EnginSoft provides training courses on the software technologies designed for the simulation of manufacturing processes. The reference software packages are those produced by MAGMASOFT.

training forge forging magma metal-process-simulation

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Our competences in Magma

CASE STUDY

Cold Forging of a Silent Block Bush Steel Sleeve

Minimize physical prototypes and reduce waste, while reducing the lead time and overall production costs

The object of this study was simulating and optimizing the cold forging process for a silent block bush steel sleeve. A silent block bush is traditionally used in the linkage system of a car suspension, in railway carriages and in agricultural machinery.

metal-process-simulation forge forging automotive

CASE STUDY

Ring Rolling of a Wind Tower Flange

A tool to reduce the level of post manufacturing defects, material wastage and overall production costs

An academic study of the hot ring rolling process at ASFO Spa, that it ended with the company using Transvalor Forge as a tool to reduce the level of post manufacturing defects, material wastage and overall production costs

energy forge metal-process-simulation

CASE STUDY

Comparison of casting simulation results and experimental data in heavy section ductile iron production

Aims to provide accurate information on cooling curves, microstructures and mechanical properties of large items for generic commercial uses

This technical article discusses a comparison study of simulated results and experimental data on the cooling curves, the microstructure and the mechanical properties inside a general commercial ductile iron casting.

die-casting metal-process-simulation magma