Solutions

MAGMA5 - fully optimize

MAGMA5 is the comprehensive and effective simulation tool for improving metalcasting quality, optimizing process conditions and substantially reducing costs in production. The software enables the establishment of robust process conditions and optimized casting layouts for all cast materials and processes. MAGMA5 is designed to predict total metalcasting quality by simulating mold filling, solidification and cooling. Residual stresses and distortion, as well as microstructure formation and property distributions can be assessed in all casting manufacturing processes. Simulations can be used in a virtual test plan to pursue different quality and cost objectives simultaneously. 

 


With its modular design, MAGMA5 contributes to cost reduction along the complete process chain of a cast component: from conceptual to final component design, tooling layout and prototyping, all the way through to process optimization, reliable production and quality management.


Interactive parametric gating and risering design

MAGMA5 is designed to support all aspects of casting manufacture, from casting design, melting and metallurgy, pattern and mold making, and casting itself through to heat treatment, fettling and repair.


 


Practice oriented approach to production engineering

MAGMA5 can be used for all cast materials, ranging from gray iron, sand and die cast aluminum, to large steel castings. MAGMA5 is also applicable to all metalcasting processes, for example allowing the die caster to design robust tooling layouts, minimize cycle times and predict reproducible casting quality, by using virtual experimentation during casting, tool and process lay-out.


Modeling capabilities for all casting processes

The cost benefits of using MAGMA5 in the production or in design are:

 

  • Avoiding metalcasting defects that arise from misruns, turbulence, oxide and slag entrainment, gas porosity, and shrinkage
  • Optimization of the filling process to provide a fast but smooth and controlled flow
  • Time savings in the robust design and dimensioning of gating and risering
  • Cost reduction from material usage through productivity, quality, and energy costs
  • Reduction of cycle times and maintenance costs
  • Establishment of robust process windows for a seamless and secure start of production
  • Increased security by checking operating points and through proven process conditions
  • Minimization of start-up costs through modifications to patterns or tooling
  • Improved communication within your company and in cooperation with customers
  • Increased customer confidence through a proactive demonstration of metalcasting competence

 


Automatic result evaluation and quantitative assessment of robust processes and optimized solutions

MAGMA5 - Metalcasting. Understanding. Robustness. Profitability.

 

MAGMA5 standard has a modular structure and contains the following functionalities for a comprehensive simulation:

 

  • A common graphical user interface for all modules
  • A project management perspective for handling of project versions
  • Parametric Solid Modeling of geometries using a CAD kernel as well as import and export of CAD data
  • Automatic meshing of geometries for the simulation
  • Comprehensive process mapping with direct access to all materials, process steps and the corresponding simulation settings
  • Definition of virtual designs and parameters for optimization runs
  • Simulation programs for the calculation of mold filling, solidification, cooling and serial casting applications
  • Interactive and automatic result evaluation. Several perspectives can be opened and edited at the same time
  • Result perspective for comprehensive visualization and evaluation of simulation results
  • Easy quantitative assessment of virtual Design of Experiments or optimization runs
  • Database module to manage thermophysical and other relevant process data required for simulation

 

MAGMA5 is modularly expandable

 

MAGMA5 can easily be linked to additional modules for specific processes, materials or quality aspects:

 

MAGMAiron, MAGMAsteel, MAGMAnonferrous

Material-specific modules allow the prediction of microstructures and properties and consider alloys and metallurgy.

 

MAGMAhpdc, MAGMAlpdc, MAGMApermanentmold, MAGMAwheel

Process modules allow the consideration of specific process requirements and to control the manufacturing process.

 

MAGMAcore+mold, MAGMAdielife

Products and functionalities for the prediction of core shooting, gassing, and purging and the assessment of die life aid in making the best use of available knowledge.

 

MAGMA HT thermal, MAGMAstress, MAGMAlink, MAGMAdielife

Modules for simulating stresses of the component after casting, heat treatment, or machining and the exchange of information based on simulation results, assures the design of cast parts for their performance.

System requirements

MAGMA5 is available for all suitable current operating systems such as Linux and Windows 7 and 8. MAGMA5 can be used on dual or multi-processor computers or massively parallel on cluster computers.