CPT International 04/2014

cptinternational

The leading technical journal for the
global foundry industry – Das führende Fachmagazin für die
weltweite Gießerei-Industrie

K SIMULATION

Consumption of weld rods in kg

800

600

400

200

0

1 2 3 4

Project

Figure 1: Consumption of weld rods

in 2011

Figure 2: Inclusions predictions are similar to the findings in real castings

surface and led to large amounts of entrapped

air, which in resulted in the creation

of reoxidation inclusions found

on the outer surface (Figure 3).

Based on these findings, measures

could be implemented to solve the problem.

The key approach was to reduce the

turbulence during filling and reduce the

contact time between air and melt. Any

remaining inclusions would be moved

into the risers.

With their growing confidence in

Magma soft, the foundry experts at

Toshiba investigated many other ideas,

with Magma 5 acting as a virtual foundry

shop. During the simulation process, it

was noticed that as long as ingates were

located directly under the risers, inclusions

would be pushed into areas between

them. Their engineers used virtual

experimentation with the gating

system to move the gates between the

risers with the idea to force the inclusions

into the feeding system. The sim-

Figure 3: Turbulent melt flow during the filling process

36 Casting Plant & Technology 4/2014

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