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Customer Comments from MAGMAacademy Events
Seminar “Evaluation of Simulation Results with MAGMASOFT® – Focus: High Pressure Die Casting”
Werner Höfer, Moneva GmbH + Co. KG Leichtmetallguss, Winterbach, Germany
“Simulation! Without training, you don’t stand a chance. I was extremely impressed with the possibilities of the simulation with MAGMASOFT®. This seminar was incredibly useful for appraising the setting options and evaluating the resulting simulation before SOP. Of course, just one day of training is not enough; however, this day opens up new possibilities.”
Basic Training Sand Casting and Process Training I – Cast Iron
Günther Wilking, Gienanth GmbH, Eisenberg, Germany
“As, up to now, I had only ever dealt with simulation results, the basic training was a good introduction to understanding how the MAGMA APPROACH works and to learning the basics of how to use the software. In the subsequent process training, I was able to extend and consolidate the knowledge acquired based on practical examples. The structure of the training sessions was very well-organized and the trainers took their time to help each participant if there were problems. All in all, a top training experience!”
CONTRIBUTION
AUGUST 2019
Evaluate Simulation Results – Derive Measures!
The range of quality requirements for modern castings is large. To be able to evaluate all essential requirements before tool production, casting process simulation and the methodology of virtual design of experiments and autonomous optimization based on it are essential aids. Both ways allow you to analyze and evaluate different concepts or alternatives at an early stage. Virtual experimentation on the screen supports you in your decision-making and ensures the setting of robust production conditions.
For the gating concept in high pressure die casting, numerous machine, die and casting-specific influencing parameters need to be considered at an early stage. The virtual design of experiments in MAGMASOFT® allows varying these variables independently.
The example featured below illustrates how to analyze basic tasks in runner and gating design using virtual design of experiments and lay out an optimized casting system early on in the development process.
For this purpose, a simplified simulation model for the virtual analysis is derived from the “current state of the art”. This model is shown in Figure 1. Afterwards, you define the relevant process parameters and quality criteria. As process parameters, the bending angle and the runner sections are varied. As quality criteria, flow characteristics (measure for the turbulence of mold filling) and the air pressure (measure for entrapped air) in the melt are chosen. For a more accurate analysis, evaluation areas are defined at several locations in the runner. With these areas, it is possible to consider these results separately and analyze them quantitatively.
Figure 1: Simplified parameterized model of the runner geometry
The variation of the two process parameters and their various combinations yield a total of 91 virtual experiments. These designs are analyzed using a full factorial design of experiments.
In addition to the classical 3D results, the designs are analyzed using statistical evaluation methods such as the main effects diagram (see Figure 2). For example, you can visualize the relationship between the air pressure as a measure for the entrapped air and the bend of the runner system. In the example shown, the air pressure in the melt is the lowest for a bending angle of 45°, whereas for a bending angle of 90°, the curve reaches a maximum.
Figure 2: Analysis of the air pressure in the melt
The second quality criterion, the cumulated free surface of the melt in the runner as a measure for the turbulence of mold filling, is analyzed using the scatter chart. The x-axis represents the runner section, whereas the y-axis shows the free surface. In Figure 3, you can see that the free surface is smaller for smaller runner sections. Likewise, the distribution of the corresponding test results in the chart allows you to draw conclusions about the robustness of the process. The narrower the distribution of the results, the more robust is your process.
Design optimum casting systems at an early stage and extend your textbook knowledge and know-how with the help of simple virtual baseline studies – MAGMASOFT® autonomous engineering supports you in doing so.
Figure 3: Analysis of the free surface of the melt in the runner for different runner sections
If you are interested in learning more about the evaluation of such virtual designs of experiments or wish to deepen your knowledge about simulation results, we invite you to visit the seminar
Evaluation of Simulation Results with MAGMASOFT® – Focus on Sand Casting/High Pressure Die Casting.
This interdisciplinary event is primarily aimed at executives and persons in charge from design, quality and purchasing departments who do not use the software in their daily work, but need simulation results for their decision-making.
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