#Complex casting magmasoft software

Having solved the curing related defects, a further core blowing analysis was carried out. Removing some of the upper and middle vents resulted in a 36% increase in the gas escaping through the lower vents. Total gas mass flow through the lower vents.

Since the venting area was reduced, some filling defects were present, as expected.ДЇigure 4. Applying these modifications, Usiminas produced another core, which did not show any gassing defects. Also, the amount of adsorbed curing gas increased in comparison to the original project. The optimization led to a considerable increase of the curing gas concentration in the lower regions of the core (~36%) (Figure 4). However, it was clear that these changes obviously would also influence the core blowing step.

Instead of making costly modifications to the core box, Usiminas determined that a possible вЂ“ and simple вЂ“ solution was to close some vents in the top and center regions, in order to increase the gas concentration in the bottom. The open venting cross section of the top and central vents was allowing the gas to escape before it reached the bottom of the core. The problematic area corresponds exactly with low concentrations in the simulation.Д®valuating simulated curves for the gas mass flow through the vents made it clear that the catalyzing gas was not reaching the critical area. Core Blown with new parameters in comparison with the local concentration of adsorbed curing gas. The core blowing and curing steps for the PU coldbox process were analyzed, making it possible to draw preliminary conclusions regarding the existing defects.ДЇigure 3. This core, called the thin waist core, represents some of the biggest challenges for Usiminas core production: its length (920 mm), substantial changes in the sand flow direction during blowing, the need to fill certain parts of the core through counter-flow and big variations in the cross section within the core.ДЇirst trials showed problems with the process, which led to a complete collapse of the lower part of the core. The main goal was to optimize the process conditions for the existing tooling layout.

#Complex casting magmasoft software

The first project on which this software was utilized was already in progress at that time. The bottom of the core collapsed due to a lack of strength.Д«razilian steel giant Usiminas recently introduced the new foundry core making simulation software MAGMASOFTВ® as part of their strategy to establish robust designs and processes for their core production line.