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Solidification modeling: How we do it with Magmasoft

The key to success

Computer aided flow and solidification modeling and simulation software is a key to success in the foundry industry today. There are several different programs on the market, but the industry leader is MAGMASOFT ®, which is the software that we use at The Lawton Standard Co.

What is it?

MAGMASOFT ® is the comprehensive and effective optimization tool for improving metal casting quality, optimizing process conditions and reducing production costs. Consequently, utilizing the methodology of virtual Design of Experiments and Autonomous Optimization, robust process parameters and optimized casting layouts can be established for all cast materials and processes including heat treatment and melt metallurgy – efficiently and comprehensively at the same time.

MAGMASOFT ® offers the following main benefits:

• Supports all cast materials and all aspects of casting manufacture including melting and metallurgy, pattern and core making, cleaning and repair

• Offers a virtual test field for the reduction of metal casting defects with high degrees of freedom without production risk

• Establishes optimized operating points for quality, yield and cost

• Identifies optimal process conditions for robust process windows early and reliably

• Allows faster decision making to establish saving time for all parties involved

• Empowers quality management by generating systematic understanding how process variability affects quality

• Improves communication and confidence within your company and in cooperation with customers

• Offers reliable and early information to designers for robust product and process development

How we use it

At The Lawton Standard Co., we use Magmasoft to simulate the filling, solidification, and cooling for new parts during the design phase before we even begin to make the patterns. Our engineers generate designs for gating and risering and use the software to validate the designs. The process for the first article sampling then begins. First, our engineering team will run a “casting only” or “bare” solidification which will identify the areas of risk in the part. This will assist in the design of the gating, the metal delivery system, and the riser and/or chill locations, the feeding system.

After the gating rigging is designed, the team then simulates the filling of the part. The software will predict areas where we could see potential defects caused by the metal filling. It also shows the metal solidifying and cooling. Our engineers will then adjust the gating and rigging design to reduce the risk of potential defects and run multiple iterations of the design changes until the issues are resolved.

Additional benefits

Our team also uses Magmasoft to solve scrap/quality issues with existing parts, but this is a more reactive approach. Simulations can be run to predict issues with the current design or identify process variation to help with the RCCA (root cause corrective action) process.

There are many factors that affect the outcome of a casting. MAGMASOFT ® allows us to have a more controlled process and predictable outcome, ensuring quality and profitability. It helps to support our engineering team to create optimal designs and process conditions.