The following examples demonstrate how our customers successfully exploit MAGMASOFT® in order to realize better casting quality, cost savings or reduction of development times especially in the area of casting design.

Analysis of Transmission Case Shrinkage Defects

In a high pressure die casting for a transmission case, a shrinkage defect was revealed after drilling of the boss. Due to the current die design, it was not possible to insert a pin into the die, making drilling of the boss the only option for this casting.

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Solving a Weighty Cracking Problem

Wheel weights are used on farm machinery to improve traction, as well as to balance tractors loaded with optional equipment. These gray iron castings didn‘t appear to have any defects after casting and did not show any obvious cracks or discontinuities during machining and painting. However, when the weights were mounted to the wheels, cracks appeared.

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Real Prototype – Realistic Casting?

Before start of production, many real castings are required for testing under realistic conditions. As with many of these prototype castings, the aluminum steering knuckle shown here was produced as a sand casting. The failure of the prototype casting in a test run would lead to design changes: heavier cross-sections to better withstand the load.

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Engine Blocks Full of Stress

Cast iron engine blocks can be found in more than half of all passenger cars. Their performance and weight are, among other criteria, dependent on their geometry and the casting process, especially defects like porosity and residual stresses.

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