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One option was a vertical position of the die and the second option was to position at 35 degrees. To improve the gravity casting method, Akebono decided to vary the casting angle (Fig. As the company aimed to improve the whole process which also included solving the remaining defect causes, they decided to use Design of Experiments (DoE) available in MAGMASOFTВ В® autonomous engineering as a standard.ДЄs a first step, the variables were defined by combining MAGMASOFTВ В® results and the previously brainstormed potential solutions. Thanks to the extended knowledge gained through simulation with MAGMASOFTВ В®, the company is now able to focus on the truly prevalent defect causes: slow velocity molten, shrinkage due to hotspot and impurity/oxide on surface molten. By simulating their current production process, Akebono manage to identify their main problems using the software.

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The software allowed the employees to virtually implement their ideas and determine which of those would lead to the best result in reality (Fig. After brainstorming, the experts wanted to validate their ideas using MAGMASOFT В®.

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The last identified driver resulting in higher porosity was shrinkage due to an existing hotspot in the casting. A next possible root cause was hydrogen content in the melt. The second cause for the problems was related to oxides on the molten surface.

Impurities and cold shut defects were assigned to a too slow melt velocity during filling. In the first brainstorming session, years of experience in foundry work allowed the employees at Akebono to directly narrow down all the possibilities to only the most likely root causes. The experts at Akebono had to find solutions for the defects to fight growing reject rates.

Two of these three problems were even intensified, depending which gating system was used. In the production of one single part, three major casting defects showed up: Impurities on the surface, cold shuts and porosity (Fig. The company manufactures master cylinders in the gravity casting process using two different gating systems. Akebono Brake Astra Indonesia is one of the foundries who implemented the methodology of MAGMASOFT В® autonomous engineering to support their experts and reduce uncertainty.

PrГјf- und Messtechnik, QualitГ¤tskontrolle.

Modellbau, Formen- und Werkzeugbau & Rapid Prototyping, Rapid Tooling & 3D Printing.

Ausleeren, Entkernen, Putzen, Rohgussnachbehandlung.

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When downloading the PDF, please leave your contact data (you will receive the download link by e-mail) and thus agree to the processing and storage of it by MAGMA casting technology GmbH in Aachen. lead to increased safety and robustness in the die casting process through common assesment of all volume deficiencies.

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shorten the time from idea to series production by optimizing venting and process.

make predictions of air entrapment and feeding porosity more accurate and decisions more justifiable.

save time and effort for the user in project design and evaluation.

The new and enhanced capabilities of predicting entrained air and shrinkage defects in MAGMAhpdc

more accurate calculation of the locking force.

evaluation of all volume deficits (entrapped air and shrinkage porosity) in one result.

extended feeding model for die casting considering the third phase.

vacuum as a variable for virtual DoE and optimization of venting.

curves for predicting the amount of air and evaluating the die venting.

new algorithms for air transport in the melt and quantitative air results.

New possibilities to predict the transport of entrapped air during mold filling offering

2022.03

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