CR (formerly CQMS Razer) foundry in Maryborough, Queensland, Australia has been using MAGMASOFT® to help them predict and solve casting problems since 2006. One of the first benefits gained after the MAGMASOFT® implementation was the reduction of casting defects and the subsequent repair work. The number of welders necessary for the repair was also reduced, which allowed CR to concentrate on more significant work.
In 2016, CR designed the DecaEdge™ cast lip, which was designed to fit large mining wheel loaders. CR is the only manufacturer in the world to offer a range of cast lips for large mining wheel loaders. The first iterations of the DecaEdge™ design required fabrication from three separately cast parts, each two meters in length. The entire process for manufacturing tied up space, as well as labour, in the workshop. The production team identified that the foundry had the physical capability to produce the part as one piece, instead of three.
The main challenge of the redesigned part was to stay within the bounds of dimensional tolerances of the finished product. The increase in size and complexity of the geometry made this a difficult task. The DecaEdge™ cast part is 6.2 m long and 1.2 m wide with a weight of 5000 kg.