Comprehensive simulation of casting processes
Comprehensive simulation of casting processes for ferrous and non-ferrous alloys, including gravity, high/low pressure, tilt, and investment casting. We analyze mold filling, metal solidification, and the formation of defects such as porosity, segregation, or hot/cold cracking. We provide predictions of residual stresses and part deformation, enabling optimization of runner design and process parameters. The solution supports mold development and quality improvement of cast parts early in the design phase.
Caliper Casting Simulation
Improvement in quality of cast components by predicting and preventing defects such as porosity, shrinkage, and inclusions, reducing the need for costly rework and ensuring safety and reliability.
Solver: MAGMArotacast to simulate the casting process that includes mold rotation during mold filling.
Accuracy: Use MAGMAtilt options to define the parameters for tilting times and rotation angle.
Predict turbulence and adjust the tilting speed for laminar flow of the liquid aluminium during casting.
Offers support in detecting possible inclusions and predicting porosities.
Shorter product development cycles.
Indicate areas that have hot cracks tendency.
High-Pressure Die Casting (HPDC) Optimization
Produce defect-free HPDC parts with consistent quality
Eliminate trial-and-error in tooling setup
Optimize gating and shot profiles for better metal flow
Improve die thermal control and solidification uniformity
Reduce shrinkage porosity, soldering, hot tears, and surface defects
Achieve targeted microstructure and mechanical properties
Software: Magmasoft
Simulate the HPDC process in full detail: Predict molten metal flow behavior, Evaluate and optimize gate geometry and location, Determine ideal injection speed and pressure profiles, Analyze and minimize risks of air entrapment, cold laps, and oxide formation, Simulate complex cavity filling and recommend flow balancing strategies, Fine-tune melt temperature, die temperature, and cooling system parameters
Integrate filling simulation with solidification and thermal analysis: Predict solidification patterns, Optimize cooling strategies, Evaluate intensification pressure needs, Minimize shrinkage and stress-related defects
Fewer iterations in die design and sampling.
Reduced cost from early detection of casting defects.
Improved mechanical properties, microstructure, and process repeatability.
Smoother production ramp-up and faster time-to-market.
