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Acciaierie Rubiera

Daniele Miceli

Optimization of process parameters in pouring of slim steel ingots


Modern steel industry aims at producing steels with higher and higher quality standard and low cost, this means steel ingots with low defect, both in terms of segregations that inclusions, and high yield. A virtual approach can be very helpful to achieve this purpose but the virtual model has to describe consistently the experimental reality. Through the software MAGMA5 we create a consistent model and then, on the basis of it, we use the software optimizer to find best process parameters to decrease the segregation of the elements.

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Giacomo Bertuzzi

Structural optimization of heavy section ductile iron components. How the integration and optimization of casting process can improve their design


The global competition is pushing the designers to reduce components mass and cost, still maintaining an high safety and quality target. This is all the more if very large items are considered, since weight reduction has not only an impact in the direct cost of the item, but also in indirect costs like machining, handling, assembly and transportation. Nowadays some companies are tacking on the weight reduction challenge using simulation tools referred as "Structural Optimization Techniques". These aim to the most efficient shape and thus are very well coupled with the casting process, which allows large freedom in terms of geometry complexity. What is often missing when the designers deal with heavy section castings is that the microstructure and mechanical properties change inside the castings due to segregation and different solidification times. In this work we analysed and compared three different design scenarios based on three different optimization workflows applied to a ductile iron casting. In the first scenario we performed a structural optimization without considering local mechanical properties. In the second one the local mechanical properties are introduced in the optimization loop and used to calculate the component reliability. The local mechanical properties are estimated using casting simulation and the component is optimized by taking them into account. In the third scenario the structural and process optimization are fully coupled: the casting process is optimized in the "virtual foundry" to reach and improve the structural target. The more integrated approach does not only reduce the total cost and increase the quality level of the component, but, implementing casting optimization, the manufacturing process cost are reduced as well since it's focused on the designer's needs. A complete automation of the proposed coupled optimization approach is still missing due to data transfer limitations and hence a more open attitude of the software is advisable.

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Stefano Polli

Problem solving and optimization: the use of MagmaSoft in hot chamber zinc diecasting


Hot-chamber zinc die casting is a process which realizes products through high pressure injection of fluid metal into the mould. Analyzing and predicting the behavior of the metal during filling and solidification is a fundamental help in mould design.

We present three case study examples describing products affected by typical defects of this process (shrinkage porosity, cavitation and turbulent flow) and how CFD simulation by MagmaSoft has been used to analyze the problem and find suitable solutions.

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Gianluca Quaglia

The integration between numerical simulation and sampling in the die casting tool standard production process


The integration between numerical simulation and sampling in the die casting tool standard production process” Nowadays, in the automotive sector, the fuel consumption decrease is quite fundamental, as strongly requested by the global market. Therefore, over the years many components have been converted into light alloys production (aluminum and magnesium above all) and moreover they are produced through die casting technology. Foundries and final customers (car producers among them), look for a tool maker as a partner who is able to provide them not only with “turnkey” die casting equipment, but also valid technological support for the development of pieces characterized by more and more variable and complex geometries and thicknesses. In the standard production process, during the mold design, from the simplest to the most complex, SAEN systematically uses the process simulation MAGMA5 software, thus reducing the casting problems, usually appearing during the first samplings and the production, as much as possible. Thanks to the experience gained through its foundry laboratory, SAEN is able to analyze and constantly compare the results of the numerical simulations and those of the samplings, modifying and optimizing the gating systems and the HPDC machine parameters used during production. Sometimes, it is possible to achieve a standardization of gating and overflow system design, for components which are different among them but belong to the same “family”. Through the experience built up in 45 years of company history, the know-how of its staff and a continuous effort in the process improvement, SAEN is able to realize even small production series (500-1000 pieces) during the first samplings of the die, thus strongly reducing the production time of first series in order to quickly answer the final customer’s needs.

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Giampietro Scarpa

High tech die casting driven by virtual experimentation and autonomous Optimization with MAGMA


Components are getting more and more complex in shape, with high performance demands, and at the same time less defects and an narrow margin of error; in other words, the design of the components requires a combination of acceptable cost, low weight, performance and easy production. In such a context, the product-process design and optimization assumes an extremely important role, since it’s a very delicate phase in which the most effective solutions are evaluated in order to produce the equipment and to optimize the proper process parameters.
The development and optimization of a casting process means to identify the variables that mainly impact on the product features, evaluating the effects with the support of advanced tools for process simulation.
CAE tools, like MAGMA and its Optimisation tool, are evolving to support the design during the research of the best engineering solution. The virtual prototype approach is interesting in particular in case of component with high performance requirements.

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