The final design was the result of several MAGMASOFT® iterations. The predicted local stresses in the critical areas were reduced by 50%. Also, the new design resulted in a 1,000 kg weight savings per casting - a considerable reduction of about 10% with corresponding savings in material and energy.
As this example shows, the manufacture and assembly of MDT’s engines is a huge challenge. This is further complicated by the fact that a centralized production would neither be ec�onomically nor ecologically sound. Therefore, MDT’s parts are produced and assembled by associates and licensees near local shipyards all around the world. To globally ensure part and engine quality, MDT has set high standards for standardization, licensing and troubleshooting. All steps from pre-engineering through production to support rely on concise documentation. Strictly defined requirements must be met by every vendor or licensee worldwide. This procedure involves three key factors: analysis, communication and documentation, all reliable and accountable. Here, MAGMASOFT® is a key tool for MDT. The software allows the identification of quality inspection areas, the validation of casting process recommendations, and helps the licensees to understand where to be careful. Furthermore, MDT uses MAGMASOFT® as a standard tool to illustrate the difficulties that can be experienced during the casting process, as the software provides an excellent platform for technical discussions.
As a result of the successful application of MAGMASOFT® on a wide range of occasions since 2006, MDT has gradually integrated the software more deeply into the company’s production and business processes. With many more tasks at hand, the new functionalities of MAGMA5 Rel. 5.3 are eagerly awaited. The new capabilities for carrying out virtual experimental trials will allow the evaluation of wider sets of potentially eligible process and design variations in less time, and the assessment and interpretation of complex results will be easier than before.