In the first brainstorming session, years of experience in foundry work allowed the employees at Akebono to directly narrow down all the possibilities to only the most likely root causes. Impurities and cold shut defects were assigned to a too slow melt velocity during filling. The second cause for the problems was related to oxides on the molten surface. A next possible root cause was hydrogen content in the melt. The last identified driver resulting in higher porosity was shrinkage due to an existing hotspot in the casting. After brainstorming, the experts wanted to validate their ideas using MAGMASOFT®. The software allowed the employees to virtually implement their ideas and determine which of those would lead to the best result in reality (Fig. 2). By simulating their current production process, Akebono manage to identify their main problems using the software.
Thanks to the extended knowledge gained through simulation with MAGMASOFT®, the company is now able to focus on the truly prevalent defect causes: slow velocity molten, shrinkage due to hotspot and impurity/oxide on surface molten. As the company aimed to improve the whole process which also included solving the remaining defect causes, they decided to use Design of Experiments (DoE) available in MAGMASOFT® autonomous engineering as a standard.