MAGMASOFT® result analysis helped in tool design optimization: MAGMASOFT® is used in the development of gating systems for all components produced at Endurance. For the flywheel housing casting, a center runner and gating system was proposed. Various gating system alternatives were created in CAD and then evaluated by means of simulation studies. Through the optimization of the runner design and the orientation of the casting, it was possible to control the temperature drop of the metal without changing the die filling time. The MAGMASOFT® filling results also helped in finding the best positions for vents and overflows. In particular, the AirPressure results were used for this purpose.
Using the MAGMASOFT® solidification results, local hot spots could be used to identify critical mass accumulations. The hot spots indicate the duration of local solidification and can therefore be used to find areas in danger of shrinkage porosity. The gating system was optimized for maximal feeding through directional solidification. Furthermore, the cooling system was optimized by studying the thermal balance of the die and its effect on the solidification.
After conducting T-0 trials, casting defects which could not be fully removed in the early stages were correlated with MAGMASOFT® results and consequently optimized by process improvements. The solutions were put in place before sample submission to the customer. T-1 samples given to the customer were validated and approved without any changes in product and tool design.