GIFA Trade Fair 2019

Full Speed Ahead on the Data Highway

| Author/ Editor: Michael Vehreschild / Isabell Page

Electric cars are gaining momentum this year, and companies are increasingly developing into intelligent factories. Trends that the casting industry can also follow in the fast lane. Innovations at GIFA's Düsseldorf trade fair quartet this week will show how companies can become even faster in their development.

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For MAGMA, simulation and Industry 4.0 are currently dominant topics.
For MAGMA, simulation and Industry 4.0 are currently dominant topics.
(Source: MAGMA GmbH)

MAGMA GmbH explains how “Autonomous Engineering supersedes traditional simulation”. Unlike pure simulations, this engineering enables users to consider opposing goals with regard to economic feasibility and quality and thus find the best compromise, according to MAGMA. At GIFA 2019, MAGMA GmbH presents their holographic theatre “MAGMASOFT – The Digital Foundry Process”. Here, visitors gain insight into Autonomous Engineering in a world premiere that opens up new opportunities for virtual cast part, tool and process optimization. For MAGMA, simulation and Industry 4.0 are currently dominant topics.

From Operating Points to Robust Process Windows

Autonomous Engineering already supports casting design, robust process design and optimised casting parts evaluation before the first cast. Using this new method, various parameters can be examined prior to the start of production. Instead of calculating a variant, the system calculates experimental space. This allows users to evaluate more possible calculations than ever before and thus enables them to pursue different quality and cost objectives at the same time.

In concrete terms, “this generates extensive knowledge for designing and controlling the entire casting process as well as concrete, practical measures, whilst taking design and process requirements into account,” explains MAGMA. Results produced by the current version MAGMASOFT 5.4 range from evaluating and optimising work flows for casting defects, residual stress and warpage to structural composition and heat treatment.

MAGMA presents the virtual core shooter, an Industry 4.0 application they developed in cooperation with their industrial partners. This application virtually depicts material flows and pressure conditions for the coupled core shooter tool for the first time. The evaluation of the entire shooting process takes milliseconds with the software developed by MAGMA. This opens potential to integrate the simulation in real-time control of core shooters, “which represents a revolutionary step towards Casting 4.0 in the field of core shooting,” emphasises Dr.-Ing. Jörg C. Sturm, Managing Director at MAGMA GmbH.

This development combines process simulation and real core production. Coupling the moulding material characteristics with the core shooter and the current tool lead to a holistic depiction of the overall process. “This makes robust core quality calculable,” explains Dr. Sturm.

Communication within a company and the ability to quickly exchange information with customers and suppliers are important requirements for using knowledge in the spirit of Industry 4.0. The company proves how easy it is to use information gained by MAGMASOFT for decisions with its new, innovative visualisation programme MAGMAinteract. Using a virtual pressure casting tool, the company demonstrates how robust tool design and optimised production windows can be simultaneously realised and securely evaluated in the shortest period of time.

No more Limits thanks to Data gained in Simulation

Numerous data cannot be captured metrologically during casting, as it is simply not possible to reach many areas of a component or cast part. This is where simulation comes into play: With this method, there are almost no limits to evaluation. “Data gained in the simulation can be placed in the Cloud in order to carry out automated regulation of a disturbance value or variation, together with measurement results gained in real production,” explains Reinhard Vomhof, Sales Manager at RWP GmbH, a corporation of consulting engineers for calculations and computer-supported simulation.

Problems are becoming more complex, which in turn requires that the various software solutions are better interconnected. Here, foundries are taking a decisive step towards Industry 4.0. RWP, a simulation software provider for casting, welding and heat treatment processes and exhibitor at GIFA, aims to support companies on their journey to becoming smart factories. A development that can no longer be stopped.

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