New Solver for MAGMAlpdc incl. CPC & MAGMAwheel in MAGMASOFT® 6.1

MAGMASOFT® 6.1 introduces significant advancements in the simulation of low pressure die casting processes. New solver technologies enhance precision and efficiency in modeling complex casting scenarios. Proven functionalities from core manufacturing, high pressure die casting, and permanent mold applications have been fully adapted for low pressure die casting, ensuring even more reliable simulation results.

The new capabilities and algorithms give you a better, more accurate picture of the complete permanent mold casting process.

New benefits for:

• Venting & air entrapment
• Movement of the free surface
• Turbulences
• Core gas and binder degradation
• Particles

New capabilities for:

• Pressure-dependent feeding
• Temperature control channels with flow
• Electric heating cartridges
• Variotherm temperature controls
• Counter-pressure casting (CPC)

Improved mesh generation with composite and True Adaptive Geometry (TAG) meshes enables a more accurate mapping of interfaces between the cast material and both mold and core materials, ensuring consistent reliability. New, additional 'Tracer' results provide a more detailed analysis of temperature, velocity, pressure and "path length", enabling a more precise tracking of melt movements and flows. This supports targeted optimization of designs and process parameters.

An optimized algorithm for surface tension modeling increases accuracy in simulating complex filling processes. In addition, the 'Air' result, adapted from the permanent mold and high pressure die casting modules, helps identify air entrapments in the casting and assess their impact on casting quality with even greater precision.

The new 'Heat-up Phase' functionality enables precise simulation of the preheating of molds, incorporating classic temperature control channels, electric heating cartridges with PI control and Variotherm temperature controls. This results in more accurate cycle time calculations and improved process control.

For counter-pressure casting (CPC), MAGMASOFT® 6.1 introduces dedicated enhancements that allow the specific definition and simulation of process parameters such as counter-pressure and pressure difference. These features enable users to better evaluate their influence of process parameters on feeding and mechanical properties of the casting.

With these advancements, MAGMASOFT® 6.1 offers a comprehensive toolbox for the efficient and precise design of low pressure die casting processes.