MAGMA presents MAGMASOFT® 6.1: Efficient and Sustainable Casting Processes

With MAGMASOFT® 6.1, the German company MAGMA presents the new release of its casting process simulation software. New functionalities and enhancements support the optimization of low pressure casting processes and simplify the design of die-cast parts. A new module covers rheocasting and thixomolding processes. A wide range of options for core production and continuous casting allow users to design process sequences both precisely and efficiently.

The new, fully integrated ECONOMICS Perspective enables users to quantitatively assess costs and CO₂ emissions based on already defined data, thus supporting sustainable and economical casting processes.

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 (c) MAGMA GmbH

Low Pressure Die Casting: Process Optimization With MAGMASOFT® 6.1

New solver technologies ensure both precision and efficiency when mapping complex casting processes. The new 'Heat-up Phase' complements the heating of the permanent mold with more flexible options for temperature control. Additional results and criteria support the analysis of both filling and solidification processes.

Highlights in MAGMAlpdc & MAGMAwheel

Porosity prediction taking into account pressure-dependent feeding (c) MAGMA GmbH

Porosity prediction taking into account pressure-dependent feeding

For counter-pressure casting, a dedicated extension is now available, taking into account both the optimization and the influence of process parameters, such as counter-pressure and pressure difference, on feeding and mechanical properties.

Pressure increase in the mold during counterpressure casting (c) MAGMA GmbH

Pressure increase in the mold during counterpressure casting

MAGMA ECONOMICS: Sustainable Production

MAGMA ECONOMICS is a new, fully integrated perspective of MAGMASOFT® that uses the capabilities of "Autonomous Engineering" for optimization and virtual design of experiments. ECONOMICS allows users to quantitatively evaluate costs and CO₂ emissions directly in the software and along the entire casting process – based on existing data. With customizable templates for common materials and processes, MAGMA ECONOMICS can compare scenarios without requiring additional simulation time, supporting informed decisions that simultaneously consider technical, economic and ecological goals.

Highlights in MAGMA ECONOMICS

MAGMA ECONOMICS Schnelle Abschätzung von Kosten oder CO2 Fußabdruck auf Basis ihrer Simulationen (c) MAGMA GmbH

MAGMA ECONOMICS Schnelle Abschätzung von Kosten oder CO2 Fußabdruck auf Basis ihrer Simulationen

Core Production: Extended Simulation Capabilities

MAGMA C+M (core production) automatically calculates the pressure applied to the shooting nozzles based on the machine parameters, enabling a realistic mapping of the overall system of machine, core box and shooting process. The calculated pressure curves integrate seamlessly into simulations and virtual design of experiments. The simulation time for gassing processes using inorganic binders has been significantly reduced. MAGMA C+M is now even more closely linked to the current machine configuration and provides robust, practical information for the real situation in the core-making shop.

Highlights in MAGMA C+M

Automatic calculation of pressure curves for core shooting (at shoot nozzles) (c) MAGMA GmbH

Automatic calculation of pressure curves for core shooting (at shoot nozzles)

Optimization in continuous casting: MAGMA CC

The variable control of the pouring velocity in MAGMA CC (continuous casting) allows a flexible mapping of "stop & go" cycles. Mechanical influences of guide rollers on the strand deformation are also taken into account. The tracking of tracer particles makes it possible to analyze how melt is distributed across different strands via launders. The extended capabilities of MAGMA CC provide new quantitative information on process-dependent strand quality and support users in the efficient evaluation of results.

MAGMA CC – Consideration of "Stop & Go"o during pouring (c) MAGMA GmbH

MAGMA CC – Consideration of "Stop & Go"o during pouring

MAGMA CC – influence of rolls on strand deformation (c) MAGMA

MAGMA CC – influence of rolls on strand deformation

MAGMAsemisolid: Innovation in Lightweight Design

The new process module MAGMAsemisolid uses a special viscosity model to take into account the specific conditions and thixotropic rheology of semi-liquid metallic melts in rheocasting and thixomolding processes. As a fully integrated, powerful tool, it helps to create process transparency and make optimum use of the potential of these manufacturing technologies.

Highlights in MAGMAsemisolid

Calculation of the thixotropic flow of the melt (c) MAGMA GmbH

Calculation of the thixotropic flow of the melt

MAGMAhpdc: Optimized Component Design in High Pressure Die Casting

MAGMAhpdc facilitates the early design of castings, even before the machine or casting system has been determined. The new "Virtual Gate" function allows positioning multiple inlets directly on the casting, while flexible casting conditions enable a quick initial assessment of the die filling process.

Highlights in MAGMAhpdc

Fast evaluation of mold filling in the component with a reduced simulation model at an early stage of product development (c) MAGMA GmbH

Fast evaluation of mold filling in the component with a reduced simulation model at an early stage of product development

Additional Innovations for Increased Efficiency in All Casting Processes

MAGMASOFT® 6.1 provides advanced tools for the simulation, analysis and optimization of casting processes. The most important innovations include:

  • Expanded material databases: New products have been added to the FOSECO Pro module, which now features Çukurova feeder datasets for the first time.
  • New measurement mode for MAGMAstress: Distance, flatness and roundness are measured directly during the evaluation, facilitating the evaluation of casting distortions.
  • 'Tracer count': Particles in the melt are counted in predefined areas.
  • 'Channel Assistant': Cooling channels are automatically generated from existing voids in the mold geometry.
  • Automatic export for MAGMAinteract®: Project results and STL geometries are automatically exported as MAGMAinteract® files, which reduces manual effort.

With these enhancements, MAGMA underlines its commitment to casting excellence: MAGMASOFT® 6.1 significantly expands the capabilities of casting process simulation and supports customers in optimizing their manufacturing processes in a targeted manner – with greater efficiency, precision and sustainability.

Highlights in MAGMASOFT® 6.1

MAGMAlpdc users benefit from numerous innovations and improvements. For example, 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

MAGMAlpdc users benefit from numerous innovations and improvements. For example, 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.

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