In this paper, analysis of steps 4 to 8 have been carried out using MAGMA software. Heat transfer with phase change(Solidification) Pouring of the hot metal into the die cavity The various steps which are involved in the production of castings with the help of die are as follows: Physical steps in Gravity Die Casting process: Proper analysis of these parameters helps us to find out the defects in the die design and make changes in the design accordingly.
FILLING RESULT IN MAGMASOFT SOFTWARE
Therefore the MAGMA software is used for simulation of the filling in of the gravity die casting and various parameters are calculated in this process. Productivity is improved, higher value castings can be taken up, and internal knowledge can be preserved for future use and training new engineers. It enables quality assurance as well as high yield without physical trials. The casting simulation technology has sufficiently matured and has become an essential tool for casting defect troubleshooting and method optimization. However, by having a proper understanding of modeling procedures, and the physical reality, this gap between physical reality and simulation results can be minimized. As a result, there will be certain deviations between practical/field/plant observations and modeling or simulation results. In any mathematical model, the physical reality is idealized and approximated. Computer simulation of casting is based on the concept of mathematical modeling of manufacturing processes. Then the casting simulation software can be used as a virtual shop floor of a casting plant to simulate various gating design options to optimize the design and to increase the yield and reduce rejections. The primary purpose of the simulation software is to predict the various casting defects such as air entrapment, residual stresses, distortion, shrinkage porosity, etc. KeywordsCasting simulation, casting defects, air entrapment, shrinkage porosity,solidification tim,MAGMAsoft.ĭesigning a new mould is often most expensive single investment in product development so we have to find out where the problems may arise before we manufacture the mould or die. The effects of these parameters on the die castings are also discussed in this paper. This paper discusses about various parameters such as cavity fill time, percentage of air entrapment in the mould after filling and cooling, velocity of metal, solidification time of metal and shrinkage porosity. A die used for making spanner castings is used in this research. The simulation results demonstrate the filling of the die cavity and show how the filling process would actually take place. Rahul T Patil, Veena S Metri, Shubhangi S TamboreĪbstractThis paper explains the application of Magma Software to model the filling of gravity die casting and using it to check the defects present, if any. Analysis and Simulation of Die Filling in Gravity Die Casting using MAGMA Software