CPT International 04/2016

K SIMULATION
with/without
Overflow 1
with/without
Overflow 2
Feeder
Geometry
Smooth
Filling
Reduce
Porosity
Figure 5: Overview of all designs, linked with the objectives in a parallel coordinates
diagram
Figure 4: Parametric geometries -
overflows and ball feeder as variables
of the experimental design
Smooth
Filling
Reduce
Porosity
ers, gates and optional overflows
( Figure 4). With this, 10 designs were
defined and calculated automatically
as a virtual experiment in MAGMA 5 .
At the same time, a smooth filling and
minimum of porosity were specified as
objectives for the optimization.
With the help of the statistical tools
in the assessment perspective of MAG-
MA 5 , the engineers were able to evaluate
the complex filling behavior efficiently
and within a short period of
time. While a traditional comparison
of conventional 3-D results did not
allow clear conclusions, the experts
were able to identify the main influencing
factors on the casting quality
by using the correlation matrix. In
addition to this, the optimal solution
was quickly determined with the help
of the parallel coordinates diagram
(Figure 5).
In the correlation matrix (Figure 6),
the comparatively small influence of
the overflows on both an optimized
Feeder
Geometry
Figure 6: Linking of process variables and quality criteria in the correlation matrix
with/without
Overflow 2
with/without
Overflow 1
feeding and a smooth filling was made
visible. By contrast, the feeder size
had a much more significant impact.
Through an increase of the feeder volume
by 3 %, the best compromise for
both objectives was identified. The final
X-ray examination of the castings
which were produced with the modified
design delivered a positive result
for all areas.
The systematic investigation of various
options by the Sandmann experts
built the basis for a successful mass production
of the caliper. Through the
implementation of the optimized layout
for an annual production of about
840,000 sound castings, around 384
tonnes of raw materials could be saved.
Reduced machining work and energy
savings led to more than 75,000 euro
in sa vings, and the scrap rate was reduced
by a factor of 10.
www.magmasoft.com
36 Casting Plant & Technology 4/2016