Simplifications for optimizations in high pressure die casting (HPDC) projects

MAGMASOFT® provides a powerful tool for the development and improvement of casting systems and process windows: optimization.

Using optimization, we can draw quick and objective conclusions about how design and process variations influence the final quality of the cast product. However, optimization can easily generate a large number of simulations, making the calculation time longer than desired.

To that end, MAGMA Engenharia do Brasil created a simple method to carry out this type of study. This methodology consists of focusing the evaluation on specific aspects of the system, in a way that the MAGMASOFT® user gains in number of possibilities and loses in the evaluation coverage.

A crucial point for this type of analysis is the use of simplifications that can be responsible for reducing the simulation time by dozens of times, and can be as varied as possible, with each case allowing one or more different types.

Choosing among the various options available is not trivial and, if you do not follow a logical and organized methodology, it can be a major source of error in the simulation. However, with experience and knowledge of MAGMASOFT® tools it is possible, within a few hours, to obtain answers that would take days to be achieved by conventional simulation methods, or even weeks to carry out practical tests, allowing you to come up with robust and optimized projects with ease and speed.

Figure 1: Simplification example for studying cold shuts in a casting. The simplified versions ran 83% faster than the original version. a) complete version with well represented defect. b) correctly simplified version, with well represented defect and reduced simulation time.

Figure 1: Simplification example for studying cold shuts in a casting. The simplified versions ran 83% faster than the original version. a) complete version with well represented defect. b) correctly simplified version, with well represented defect and reduced simulation time.

Figure 2: Flowchart of simplification methodology for optimizations in MAGMASOFT®.

Figure 2: Flowchart of simplification methodology for optimizations in MAGMASOFT®.

The usage of simplifications to perform optimizations in high pressure die casting (HPDC) was explained by MAGMA Engenharia do Brasil in a webinar that took place on April 30, 2020.

If you are still not familiar with the usage of optimization in MAGMASOFT®, or are familiar and seeking to improve, do not miss the chance and watch our latest webinars!

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