MAGMASOFT® 6.1 – Advancing Low Pressure Die Casting and Sustainability

MAGMA, a leading German developer and supplier of software for the simulation and optimization of casting designs and processes, introduces MAGMASOFT® 6.1, the latest version of its casting process simulation software. With extensive revisions and new functionalities, the software enhances the simulation of low pressure die casting processes, and expands the capabilities for die casters and users of MAGMA CC and MAGMA C+M. For the first time, MAGMASOFT® includes a dedicated process module for rheocasting and thixomolding. In addition, a new ECONOMICS perspective enables users to quantitatively assess costs and CO₂ emissions based on already defined geometry, material and process data. These innovations provide faster, more precise results, promoting sustainable and economically optimized casting processes.

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 (c) MAGMA GmbH

Extended Low Pressure Die Casting Applications

MAGMASOFT® 6.1 introduces significant advancements in the simulation of low pressure die casting processes. New solver technologies enhance precision and efficiency in modeling complex casting scenarios. Proven functionalities from core manufacturing, high pressure die casting and permanent mold applications have been fully adapted for low pressure die casting, ensuring even more reliable simulation results.

Improved mesh generation with composite and True Adaptive Geometry (TAG) meshes enables a more accurate mapping of interfaces between the cast material and both mold and core materials, ensuring consistent reliability. New, additional 'Tracer' results provide a more detailed analysis of temperature, velocity, pressure and "path length", enabling a more precise tracking of melt movements and flows. This supports targeted optimization of designs and process parameters.

An optimized algorithm for surface tension modeling increases accuracy in simulating complex filling processes. In addition, the 'Air' result, adapted from the permanent mold and high pressure die casting modules, helps identify air entrapments in the casting and assess their impact on casting quality with even greater precision.

The new 'Heat-up Phase' functionality enables precise simulation of the preheating of molds, incorporating classic temperature control channels, electric heating cartridges with PI control and Variotherm temperature controls. This results in more accurate cycle time calculations and improved process control.

For counter-pressure casting (CPC), MAGMASOFT® 6.1 introduces dedicated enhancements that allow the specific definition and simulation of process parameters such as counter-pressure and pressure difference. These features enable users to better evaluate their influence of process parameters on feeding and mechanical properties of the casting.

With these advancements. MAGMASOFT® 6.1 offers a comprehensive toolbox for the efficient and precise design of low pressure die casting processes.

Highlights in MAGMAlpdc & MAGMAwheel

Fig. 1: Pressure-Dependent Feeding - 'Porosity' (c) MAGMA GmbH

Fig. 1: Pressure-Dependent Feeding - 'Porosity'

MAGMA ECONOMICS: Focus on Sustainability and Profitability

MAGMA ECONOMICS is a new perspective in MAGMASOFT® that allows users to quantitatively evaluate both the economic and the ecological impact of process variants. By utilizing already defined geometry, material and process data along with simulation results, MAGMA ECONOMICS calculates and compares costs, energy consumption and CO₂ emissions across different scenarios, enabling informed decision-making.

Customizable templates for common materials and processes incorporate specific cost and emission factors. This enables a detailed analysis of resource consumption and manufacturing costs throughout the entire casting process simulation chain – from mold or tool preparation, to the pouring process, and even potential machining.

With MAGMA ECONOMICS, users can vary process parameters individually and compare scenarios without investing additional simulation time. This capability facilitates informed decisions that align with both technical requirements and cost or resource objectives.

For example, a foundry can determine which design of a casting layout minimizes CO₂ emissions while maintaining product quality. MAGMA ECONOMICS automates the calculation of CO₂ balances and production costs, simplifying the optimization of both ecological and economic performance.

Fully integrated into the standard version of MAGMASOFT®, MAGMA ECONOMICS requires no additional modules or licenses, providing users with a powerful tool for developing more sustainable and economical processes.

Highlights in MAGMA ECONOMICS

Fig. 2: The new MAGMA ECONOMICS perspective supports users in quantitatively evaluating the economic and ecological impact of process variants. Customizable templates for common materials and processes contain specific cost and emission factors to precisely analyze resource consumption and production costs. (c) MAGMA GmbH

Fig. 2: The new MAGMA ECONOMICS perspective supports users in quantitatively evaluating the economic and ecological impact of process variants. Customizable templates for common materials and processes contain specific cost and emission factors to precisely analyze resource consumption and production costs.

MAGMA C+M: Increased Efficiency in Core Production

MAGMASOFT® 6.1 extends the functionality of MAGMA C+M (Core and Mold) to simulate core production even more precisely and efficiently. A new "pressure calculator" automatically determines the pressure applied to the shoot nozzles based on machine parameters, eliminating the need for manual input. This provides a more realistic foundation for optimizing shooting parameters and enhances the mapping of the overall system, consisting of the machine, core box and process. The calculated pressure curves integrate seamlessly into 3D simulations, enabling more accurate results and earlier identification of potential defects in the core manufacturing process.

The simulation of gassing processes using inorganic binders has also been significantly accelerated, reducing calculation times by up to 80 percent. This improvement allows users to test more variants in less time. Enhanced visualization tools simplify the analysis of complex relationships and the derivation of optimization measures, ultimately increasing both the quality and the efficiency of core production.

Fig. 3: Automatic Calculation of Pressure Curve for Core Shooting (at Shoot Nozzle) (c) MAGMA GmbH

Fig. 3: Automatic Calculation of Pressure Curve for Core Shooting (at Shoot Nozzle)

Fig. 4: MAGMA C+M benefits from a revised “Core Sand” database (c) MAGMA GmbH

Fig. 4: MAGMA C+M benefits from a revised “Core Sand” database

MAGMA CC: Optimization in Continuous Casting

MAGMA CC 6.1 introduces significant innovations and enhancements for the simulation of continuous casting processes. A flexible design of pouring velocity now accommodates pauses, return strokes and cyclical movements within the withdrawal process and simulates them. This "stop & go" cycle can be mapped across the entire withdrawal process, thus simplifying the analysis of complex process sequences.

Another focus is on the detailed consideration of mechanical influences. MAGMA CC now makes it possible to precisely simulate not only the influence of the mold but also the influence of guide rolls – especially in continuous steel casting. This enables users to better analyze how roller position errors or other mechanical influences affect the deformation of the strand and, ultimately, the product quality.

In addition, the turbulence model in MAGMA CC has been extended to describe the flow behavior more accurately – especially in the sump area. This provides deeper insights into the flow dynamics of the continuous casting process while improving the simulation accuracy.

Fig. 5: MAGMA CC - Stop & Go (c) MAGMA GmbH

Fig. 5: MAGMA CC - Stop & Go

Fig. 6: MAGMA CC - Influence of Rolls for Displacement (Stress) - Improved rolls contact  (c) MAGMA GmbH

Fig. 6: MAGMA CC - Influence of Rolls for Displacement (Stress) - Improved rolls contact

Innovation in Lightweight Design: MAGMAsemisolid

MAGMAsemisolid is a new process module for MAGMASOFT® that has been specifically designed for simulating semi-solid manufacturing processes such as rheocasting and thixomolding. These processes are particularly suitable for lightweight design applications with aluminum and magnesium alloys.

A specially developed viscosity model realistically replicates the thixotropic flow behavior of semi-solid metal suspensions, accounting for dependencies on shear rate, temperature and time. This enables accurate simulations and comprehensive optimization of process parameters to produce components with higher quality and reduced scrap rates.

Detailed analyses of material distribution and solidification behavior support users in both developing new designs and refining existing processes. MAGMAsemisolid also offers an intuitive user interface that facilitates access to important simulation data. Results can be clearly visualized and exported for further analysis. In combination with other MAGMASOFT® modules (e.g., MAGMAstress), MAGMAsemisolid supports the continuous optimization of the entire manufacturing process.

With MAGMAsemisolid, MAGMASOFT® 6.1 extends its functionality with a powerful tool for semi-solid processing and helps users fully leverage these innovative manufacturing technologies.

Highlights in MAGMAsemisolid

Fig. 7: Now integratet into MAGMASOFT®: a rheological model for semi-solid metal slurries with temperature and shear-rate dependent viscosity (thixotropic flow behavior). (c) MAGMA GmbH

Fig. 7: Now integratet into MAGMASOFT®: a rheological model for semi-solid metal slurries with temperature and shear-rate dependent viscosity (thixotropic flow behavior).

Further Improvements and Enhancements

MAGMASOFT® 6.1 introduces a wide range of additional features and enhancements that make casting simulation even more efficient and precise.

The new "Virtual Gate" function in MAGMAhpdc enables die casters to position multiple inlets directly on the casting and reference the gating system to them. This enables a quick initial assessment of the die filling process without explicitly defining the gating system, shot chamber, or shot parameters.

For users of MAGMAstress analyzing casting distortion, a new 'Geometric Dimensions' measurement mode has been introduced. This feature simplifies the evaluation process by enabling direct measurement of distances, flatness and roundness during result assessment, considerably enhancing evaluation accuracy and ease of use.

The new 'Volume Wrap' function allows users to group several volumes into a geometric shell, significantly improving the display of results and supporting better analysis and more effective optimization of process parameters.

For simulating permanent mold processes, a new channel assistant has been integrated. This tool automatically detects voids in the mold geometry and generates cooling channels, streamlining the integration of cooling channels while improving the overall temperature control throughout the casting process.

A new particle counting feature, available in all process modules and products, tracks selected tracer particles. For example, users can localize unwanted inclusions in the casting at an early stage. The results can be visualized over time and contribute to more effective quality assurance.

The expanded feeder databases in MAGMASOFT® 6.1 include updated products in the FOSECO Pro Module, featuring Çukurova feeder sleeves for the first time. This addition provides users with access to the latest developments in feeder technology, broadening the range of feeder solutions available during simulations.

MAGMASOFT® 6.1 has been enhanced with automatic project export functionality, significantly reducing manual effort and making critical data more accessible for MAGMAinteract®, the stand-alone, free-of-charge application for visualizing MAGMASOFT® simulation results.

With these extensive innovations, MAGMASOFT® 6.1 reaffirms MAGMA’s commitment to casting excellence, empowering users to achieve more efficient, precise and sustainable manufacturing processes.

Highlights in MAGMASOFT® 6.1

Fig. 8: MAGMAlpdc users benefit from numerous innovations and improvements such as new, additional 'Tracer' results that make it possible to track melt movements and flows more precisely and to optimize design and process parameters in a more targeted manner. (c) MAGMA GmbH

Fig. 8: MAGMAlpdc users benefit from numerous innovations and improvements such as new, additional 'Tracer' results that make it possible to track melt movements and flows more precisely and to optimize design and process parameters in a more targeted manner.

Fig. 9: MAGMASOFT® 6.1 has been expanded to include the counter-pressure casting (CPC) process. This enables a specific definition and simulation of process parameters such as counter-pressure and pressure difference. (c) MAGMA GmbH

Fig. 9: MAGMASOFT® 6.1 has been expanded to include the counter-pressure casting (CPC) process. This enables a specific definition and simulation of process parameters such as counter-pressure and pressure difference.

Fig. 10: With the new 'Virtual Gate' function, die casters using MAGMAhpdc can position multiple inlets on the casting and reference the gating system directly to them. (c) MAGMA GmbH

Fig. 10: With the new 'Virtual Gate' function, die casters using MAGMAhpdc can position multiple inlets on the casting and reference the gating system directly to them.

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