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This meant a savings of 5,400 Euros per year for the annual production rate of 12,700 units. Savings at shake-out: Using simulation, the gating and riser geometries for the casting of bearing blocks was modified so that they could be removed by breaking them off rather than by sawing.This led to reduced operating and logistic costs. Cooling times: Predictions of both solidification and cooling times for critical parts made it possible to reduce processing times and to optimize the needs for both cooling space and the number of mold frames.This meant a significant reduction in the amount of liquid iron required and resulted in savings of 32 Euros per part and 38,000 Euros per year.

Optimization of casting rigging: The casting process for a gear wheel was optimized, so that only two risers had to be used instead of five.

The yield was enhanced from 16 % to 53 %, the cost per roll bearing decreased by 2.18 Euros.

Molding: Simulation made it possible to use a four-cavity mold instead of a three-cavity mold for roll bearings, while reducing the number of risers at the same time.

Reduction of material input: The optimization of 38 parts (with a total annual production of 31,945 units) with MAGMASOFTВ® reduced the return scrap by 295 tons in the first year of usage.

The following examples show what savings and constructive optimizations were achieved using casting simulation at every step of the process chain: вЂњWe use MAGMA simulation technology throughout the entire product and process development process in order to save materials and costs in a highly price-sensitive market, on the one hand, and to drive innovation and optimize component integration on the other,вЂњ explained Hans FrieГџ, Director of Planning/Material Management. Using MAGMASOFTВ® the planning epartment Pattern and Casting Engineering bridges the gap between computer-aided product design and actual production. This level of quality is achieved by continuous IT support over the entire production process, from design of the components and patterns to the stable computer controlled melting and pouring processes.

We see casting as part of an overarching process, beginning in design and finishing in reliably functioning, competitive products,вЂќ Schimmel said when formulating the mission of the foundry. вЂњWe have a clearly defined goal: economical casting production with consistently high quality.

MAGMASOFT TECH LEVELS FREE

Free market competition does not just make economic sense it also serves to ensure that all processes are focused on achieving the highest quality. This is because the quality of each press depends to a significant degree on the quality of the castings produced in Amstetten.ДЄmstettenвЂ™s staff do not just produce castings for the Heidelberg Group: 50 external companies order large and small castings in differing batch sizes from the Amstetten foundry. вЂњFor our customers, just like for ourselves, the decision for Heidelberg is always a decision for quality,вЂќ is how JГјrgen Schimmel, Head of Pattern & Casting Engineering described the companyвЂ™s vision, which the foundry implements on a daily basis together with the 450 employees involved in casting production. The cast parts, such as printing press side panels and cylinders, are core elements of the sheet-fed offset presses, which Heidelberger Druckmaschinen AG provides to customers in the print media industry worldwide. It acts as a center of excellence for the manufacture of cast-ings for the entire Heidelberg Group, which has annual revenues of 2.3 billion Euros (2009/2010) and 15,000 employees. For further information how we process your personal data, please follow this link Privacy Policy.The Amstetten factory is one of the most up-to-date and efficient foundries in all of Europe. It will not be passed on to third parties.

MAGMASOFT TECH LEVELS DOWNLOAD

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Availability by addressing metallurgical and material specifics for grey, ductile and compacted cast iron grades.

Reduced cost by avoiding scrap through optimized process parameters.

Robust and optimized gating and feeding designs.

Increased safety by accurately predicting porosities.

MAGMAiron quantitatively predicts microstructure and porosity for cast iron as a function of alloy composition, metallurgical state of the melt and inoculation effects and offers

Flow resistance in mushy zones during solidification.

Graphite expansion and austenite shrinkage.

Atmospheric and local metallostatic pressure on feeding flow.

Inoculation effects on precipitated eutectic graphite.

Convective heat transport during solidification.

Quantitative prediction of shrinkage related defects with a new powerful feeding model taking into account

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