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More Efficient Casting Process Simulation 更高效的铸造工艺模拟技术


Casting process simulation enables designers to deter- mine manufacturability, properties and estimated costs. By analyzing for potential defects early in the design phase, the costs associated with eliminating them can be reduced. MAGMA5 5.2, the latest release from MAGMA Foundry


Technologies, Schaumburg, Ill., features more than 160 improve- ments to increase the efficiency of evaluating simulation results. It allows the direct comparison of up to four different project


versions in the result perspective. Filling, solidification and stress results can be animated in a synchronized mode. Te software also allows for the consideration of the economical feasibility of proposed designs. Users can quickly analyze various proposed design alternatives to make decisions such as whether a feature on a casting should be cast as part of the design or if it should be machined in later. “A special highlight is the option to display the geometry


and all results in 3D stereo, using shutter or red/cyan 3D glasses, and to store them as 3D images or movies,” said MAGMA President ChristofHeisser. Te program identifies defect potential using filling and


solidification simulations. It allows for the comprehensive de- velopment of the casting, gating system and process parameters. New result criteria allow for a more effective evaluation of metal cooling and critical metal speeds during filling. Te progress of feeding and porosity formation can be monitored and displayed continuously during the entire solidification process. “Various new tools facilitate a standardized result evalu-


ation, improving the communication between production engineers and designers,” Heisser said. “For example, a new criterion to predict cracks allows the user to find stress-related casting quality problems more quickly. It is now also possible to quantitatively assess casting distortion and compare these virtual measurements with the real part geometry.” User results can be defined and created automatically during


a simulation or subsequently in the result perspective. Diecasting users will find an improved visualization of the


process time line and extended consideration of the heat transfer conditions between die casting and die as a function of the local feeding conditions. Te MAG- MAhpdc module now supports the assessment of the real casting temperature as a function of the current shot sleeve conditions. A new “resume point” capa- bility allows flexibility in


Technical understanding of the entire process is achieved through three- dimensional visualization of the entire process at all points in time.


铸造工艺模拟可让设计者确定可制造性、性能、和预 算成本。早在在设计阶段,通过分析产品的潜在缺陷, 可以减少排除产品缺陷有关的费用。 MAGMA5 5.2是MAGMA德国公司发布的最新版 本,有超过160处的升级、改进以提高评估模拟结果的 效率。


模拟结果可实现多达4个不同项目版本在同一结果界 面进行直接对比。可同步化动态展示充型、凝固以及 应力场。软件也考虑到了各种推荐设计方案的经济可行 性。用户可以快速地分析各种可选择的设计方案做出决 策,如某部位是可直接铸出还是需要后期机加工。 MAGMA北美公司总裁ChristofHeisser说“新版本 的亮点是我们使用快门或红/青三维眼镜可观测铸件三 维几何体和模拟结果的立体效果,而且可存储为三维影 像或电影”。


软件程序通过充型和凝固模拟来识别潜在缺陷。他允 许铸件、浇注系统和过程参数的综合发展。新的模拟结 果标准更有效地评估了充型过程中金属液的冷却和关键 速度。软件可监测并连续地展示整个凝固过程中的补缩 进展和气孔形成。


“各种新工具使标准化的结果评估更便利,增进了产 品工程师和设计者之间的交流。”Heisser说,“用户 可通过新的预测裂纹的准则来更快的发现与应力有关的 铸件质量问题,现在软件可以量化评估铸件变形并把这 些模拟变形结果同真实几何尺寸进行比较。” 无论在模拟过程中或者结果展示阶段,用户可以自定 义结果并能自动生成。


压铸用户将发现过程时间线的可视化得到了改进,作 为一项局部补缩条件的功能,更多地考虑了压铸件与模 具之间的热传条件。MAGMA高压模块可评估真实的铸 件温度,作为当前压射缸条 件的一个功能。


基于前一个或倒数第二 个铸件周期,一种新的“重


通过全过程各方面的三维可 视化展示完成了整个工艺过 程的技术理解。


February 2013 FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 67


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