MAGMA

Fonderie De Riccardis has at its disposal powerful MAGMA simulation software installed in an HP dual core workstation. The software has been calibrated to adhere closely to the characteristics of the Fonderie De Riccardis process, from a metallurgic point of view (e.g. chemical analysis of cast iron, eutectic temperatures, etc.) as well as the type of materials used for casting (e.g. moulding castables, cores, feeders). The simulator, after automatically generating a mesh, simulates, according to the settings received from the foundry technicians and calculating the finished differences, filling and solidification and evaluates the residual stress in the casting. The powerful MAGMA-iron module, with the help of micropatterning tools, provides a simulation, also from a metallurgic point of view, of the solidification of the cast iron and predicts metallographic mechanical and structural properties. The simulation carried out by the MAGMA system predicts the formation of any defects that might compromise the quality of the casting before it is even cast. The MAGMA-stress module simulates residual stress that accumulates in the casting during solidification and verifies distortion or cracks. MAGMA-stress maps residual stress levels, on the basis of which the foundry technicians can provide the designer with helpful suggestions for the geometric modification of the casting. The maps of the casting residual stress levels can be exported to structural calculation software as the starting point for an evaluation of the working conditions of the assembled group. MAGMA-stress is an important tool during the co-design stage. Fonderie De Riccardis benefits from a MAGMA-Frontier, an optimiser that is automatically capable of establishing the best conditions for the casting feed, by means of a series of simulations carried out with the MOGA genetic algorithm starting with an initial DOE. MAGMA-Frontier is capable of determining, for example, the most economical and efficient feed system that guarantees a perfect casting, as well as the ideal position for the unit or the geometric characteristics and ideal position for the casting gates and attachments, etc.