West Midlands, Birmingham & Coventry Branch Technical Lecture & Webinar

COMPLEX SAND CASTINGS – ‘RISING TO THE GRAND CHALLENGES’

On Monday 2nd November 47 Members and guest from the West Midlands, Birmingham and Coventry Branch Members and further afield were treated to a high standard technical lecture and webinar presented from Aachen, Germany by Dr Horst Bramann, Executive Manager Sales & Engineering MAGMA GmbH, entitled ‘Advanced Casting Simulation Technology’.

The presentation was of a very high standard and provided a highly informative demonstration of the current casting simulation technology and the power of the new digital world that is being embraced by foundries around the world.

Advanced Casting Simulation Technology’

Dr Horst Bramann began by outlining the MAGMA GmbH company profile, numbers of staff and their work locations; he himself based in Aachen.  He then expertly explained how MAGMA, which is a filling and solidification modelling software (and more), can be used as a virtual design and development process at the feasibility stage of the casting manufacturing process.  MAGMA helps by providing a fast way of determining optimized robust solutions.  It uses a targeted and systematic problem solving approach and using the mathematical philosophy of the Design of Experiments, combined with an Autonomous Engineering aspect where there is the ability to analyse multiple options simultaneously, and to then be able to judge/rank the outcomes and optimise the design.

Furthermore, a Correlation Matrix is produced that helps the foundryman to understand their process variables, quality criteria and a measure of the relative effect of the different areas of a process.

Horst gave an example of a gate length and area optimisation on an oven/cooker casting, using the mathematical statistics approach, demonstrating how the software can automatically choose the best options.

He also expertly showed his experience when explaining the dynamic variables affecting solidification that need to be taken into account, to make a robustly good quality casting, ie melt quality, inoculation and mould stability.

As referred to earlier, apart from just the filling and solidification modules in the software package, there are also modules to model core blowing/shooting, core distortion and gas evolution.

To quote Horst ‘Knowledge is only useful if it is shared’ and the MAGMA users can share and learn from one another at regular workshops.

The level of interest was clearly displayed during this high-quality talk as shown in the extent of the Q and A session at the end of the lecture.

For a copy of the presentation please contact Nicci: info@icme.org.uk