See some of the most relevant publications about MAGMA applications and developments especially in the area of casting design.

Simulation Evolves to Autonomous Optimization

Today’s requirements on the development of a casting and the corresponding metal casting process demand methodologies and tools which allow a maximization of process robustness and profitability at the earliest possible point in time. Opposed to real-world trials, autonomous optimization using simulation tools provides significantly more flexibility.

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Autonomous Optimization of Casting Processes and Designs

Twenty years after the introduction of simulation software for foundries into the industry, casting process simulation has become an accepted tool for process and design lay-out. Casting process simulation always displays the status quo of its expert user. The user decides if the rigging system or process parameters lead to an acceptable result. Additionally, proposals for optimized solutions have to come from the operator. One of the biggest benefits of the casting process is also its biggest downfall: Everything happens at the same time and is coupled. Changes in one process parameter impact many casting quality defining features during the process. Multiobjective autonomous optimization offers a way out.

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Implementation of Casting Simulation for Increased Engine Performance and Reduced Development Time and Costs – Selected Examples from FORD R&D Engine Projects

The application of CAE is continually gaining in importance in all areas of engine development. This is especially true for the simulation of the casting process as well as for the following heat treatment. Although the durability analysis of the finished component has long been an established part of the development process, CAE-technologies for the simulation of the manufacturing process have only recently come into focus. The advantages of simulation at an early stage are obvious.

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Exploit the Casting

Standard CAE procedures for engine castings typically do not account for inhomogeneous properties and residual stresses, while advanced engine design optimization suffers increasingly from a mismatch between CAE durability prediction and test bed results in the context of ever increasing performance / weight ratios. These manufacturing process related characteristics need to be known and considered early in the design process. The key to success is “Integrated Casting Process Simulation”. This technology allows to predict local properties and residual stresses and to feed them into the FE analysis and durability calculations.

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