Die Casting Publications

Dr.-Ing. Horst Bramann, M.Sc. Laura Leineweber, Dr.-Ing. Jörg C. Sturm, MAGMA Gießereitechnologie GmbH, Aachen, Germany

Innovative automotive lightweight designs lead to a higher demand for the product and process development of die cast components. This is attributed to shorter and shorter product development cycles as well as the rising functional integration and complexity of structural die cast parts. The main objectives of the technically complex processes and tools in aluminum and magnesium die casting are cost and resource efficiency along with the robust fulfillment of the defined high-class requirements of the casting. In this context, casting process simulation is a well-established tool used to support tool design, part design as well as process development.

Using the example of a structural die cast part this paper demonstrates how the new methodology of Autonomous Engineering of MAGMASOFT® 5.4 contributes to the demands of die casting for:

• faster product and process development,
• optimum process and tool design in terms of quality, yield and costs, as well as
• robust process layout with maximum reproducibility of quality better than ever before.

Autonomous Engineering expands on the virtual experiment of casting simulation by defining the quantifiable objectives, critical variable process parameters and their variations as well as relevant quality criteria. In addition to the identification of reliable technical solutions, this new approach provides the best compromise between the quality and economic efficiencies the die caster is always striving for.

Please read the complete publication in the linked PDF.