Specialists in Simulation for Iron, Steel, aluminium & investment castings
- MAGMASOFT simulation for accurate metal flow, solidification & core behaviour
- Optimises filling & runner design to reduce turbulence & defects
- Highlights hot spots & feeding needs for improved cast integrity
- Predicts core distortion & thermal stresses to prevent cracking
Want to discuss Magmasoft Simulation?
Telephone: 0121 556 4451
Email: sales@newbyfoundries.co.uk
WHAT IS CASTING SIMULATION?
Casting simulation is a process where software is used to model the filling and solidification of castings, allowing engineers to assess process performance. Simulation results can be used to appraise runner system designs prior to tooling manufacture, and casting simulation is a cornerstone of defect analysis and the fault-finding process.
At Newby Foundries, we use MAGMASOFT simulation software. MAGMASOFT is an industry standard software package with modules available for every stage of a casting product’s life cycle, as well as workflows for a wide variety of casting processes and materials.
MAGMASOFT is crucial for simulating metal flow, solidification, core performance and thermal stresses as part of our New Product Introduction (NPI) process. Through simulation, we aim to shorten lead times through right-first-time solutions.
FLOW SIMULATION
An important criterion for runner system design is smooth, controlled filling at an appropriate temperature, to ensure that moulds can fill fully before the metal begins to solidify. Flow simulation delivers a full three-dimensional plot over time of the metal’s temperature throughout the filling process, and MAGMASOFT includes tools for robustness analysis to ensure consistent performance. Turbulence during filling is a major contributor to formation of oxide inclusions, as turbulent flow mixes the molten metal with air. By using air entrapment, oxide tracer and metal velocity results, flow simulation can be used to address these risks and improve the quality of castings.
SOLIDIFICATION
The nature of solidification of a casting has a great effect on the integrity and physical properties of the finished product. Simulating the solidification of castings allows these properties to be optimised through thermal modulus analysis, highlighting hot spots and identifying key areas where feed metal is required. This process also helps with Design For Manufacture (DFM), as geometric improvements can be tested and finalised over multiple iterations.
CORE PERFORMANCE
MAGMASOFT also has sophisticated tools for maximising the performance of sand cores. The software includes detailed datasets for a variety of core materials, enabling prediction of core off-gassing and physical strength under the intense thermal loads of filling and solidification. MAGMAstress allows engineers to design mould vent positions based on the demands of the core geometry, and to determine the likelihood and impact of core distortion on the finished product. When used early in the design process, this powerful tool facilitates the manufacture of casting with challenging core geometry whose behaviour would otherwise be difficult to forecast.
STRESS ANALYSIS
As a casting cools from a molten to a solid state, different parts of it solidify at different rates. This means that the rate of thermal contraction is variable across the casting, and this results in a build-up of stress. MAGMAstress is an add-on to MAGMASOFT which can calculate stresses during solidification, fettling, heat treatment and machining, giving engineers the opportunity to address hot tear, cold crack and distortion concerns in challenging alloys prior to manufacture. This is particularly valuable for steel castings, which exhibit especially high internal stresses, and heat treated aluminium castings, which can show local cracking if quenching parameters are not well-controlled.
Working with Newby Foundries
Established since 1890, Newby Foundries provides an industry-leading service for our casting processes. We’re trusted throughout the UK and worldwide to deliver complex and challenging casting solutions.
Offering a number of casting materials and processes across our 4 sites allows Newby Foundries to provide impartial advice on the most efficient and effective process for your project.
We work across many industries, including automotive, marine, and defence amongst others, supporting our clients from design and prototyping through to production and finishing.
Sectors
NEWBY FOUNDRIES OPERATE IN THE FOLLOWING INDUSTRIES:
Automotive
EV
Hydraulic
PUMP
MARINE
Oil & Gas
Rail
Defence
Construction
Engineering
Divisions
Explore the Newby Foundries Group
The Newby Foundries Group produce high quality castings in a variety of materials, sizes & finishes across our 4 sites. Our range of casting processes, combined with our ability to develop castings from prototype through to production means we can provide customers with an optimal casting solution for many applications.
Contact us to arrange a consultation or to chat to one of our team members today.
General Enquiries
Newby Foundries are specialists in Iron & Steel Sand Casting, Rapid Prototyping and Investment Casting. Contact us to arrange a consultation or to chat to one of our team members today.
For more specific enquiries for our individual foundries, please find contact details on our contact us page.
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Telephone: +44 (0) 121 556 4451
Email: sales@newbyfoundries.co.uk
Head Office:
Newby Foundries Ltd
Smith Rd, Wednesbury, West Midlands, WS10 0PB, United Kingdom