The quality and profitability of iron castings are driven by the metallurgy of the melt, the design of the pattern, the productivity of the process, reproducible manufacturing conditions and the resulting properties of the cast iron material after casting and heat treatment.
MAGMASOFT®, with the latest version MAGMA5 and its related modules are capable of autonomously establishing robust process conditions and optimized solutions for the pouring, solidification and heat treatment of all cast iron alloys. The integrated tools to statistically set up virtual Designs of Experiments and automatically assess results support foundrymen in determining optimal design and process conditions, for example regarding:
MAGMASOFT®’s unique integrated methodology of virtual experimentation and autonomous optimization lets the software automatically run through various iron casting design and parameter combinations. MAGMASOFT® helps identify a set of process conditions best meeting the specified requirements. This is done quickly and comprehensively, matching different objectives considering all driving forces decisive for iron casting quality.
This makes MAGMASOFT® key for casting designers, pattern makers and foundrymen to lay out optimal cast component designs, implement reliable production processes, minimize quality risks, set up reliable process windows and realize the full potential of cast iron materials.
When less is more
Producing large ductile iron axle housings can be a challenging task. The part shown above was well into production when a shrinkage defect was noticed during machining. After several attempts to find a solution, the foundry contacted MAGMA to evaluate the part design.