The simulation of heat treatment is also seamlessly integrated. With the integration of all important process steps in die casting, the virtual process chain is represented realistically: from ejection, quenching and cooling of the casting, through trimming of gates and overflows, to consideration of the residual stress redistribution caused by machining of the as-cast part.ĭie casting tool design is supported by the calculation of contact pressures between casting and die, now including the prediction of the corresponding required ejector forces (Fig. Market Review The Indian Aluminium High Pressure Die Casting Industry
MAGMASOFT® 5.4 now additionally offers an intuitive visualization for all casting processes of the thermal balance between the casting and the die for the quantitative evaluation of energy exchange over the complete process, in individual process phases, or for defined time intervals (Fig. The flow within cooling lines, spot cooling or conformal cooling near the die contour can be optimized for increased thermal efficiency, by taking into account the cooling medium with its inlet/ outlet conditions, temperatures, and flow rates (Fig. This enables an even more precise evaluation of the influence of spraying on the thermal balance in the tooling, the distortion of casting and die components, or local die lifetime (Fig. Magmasoft Optimizes Autonomous Engineering Die Casting Simulation of the Spraying Processīased on the level of detail required to achieve a given objective, MAGMASOFT® 5.4 offers various capabilities for optimizing the spraying process in both die casting tooling and process development: a classical approach with uniform heat extraction from the cavity in early-stage product optimization, an extended approach with user-defined static or movable spray areas, or even the realistic consideration of the spray head with individual circuits, nozzle positions, and programming of the head movement. The consideration of the available machine capacity (PQ2 diagram), the venting conditions and the complete thermal balance in the die, which are all critical for casting quality, can be evaluated at the earliest stages of process and tooling design. This enables the optimization of dosing parameters, dwell times, plunger velocities, and switching points. With these new features, the software enables the detailed investigation of the dosing process and the shot profile considering the shot chamber geometry (Fig.
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