Why I believe in MAGMASOFT®

From its conception, the founder's work is based on tacit knowledge: The final result of each piece is not appreciable until demolding.

For this reason, I reluctantly accepted the benefits of incorporating digital tools into production processes: "It's too expensive", "What do we do, is good" or "what for?" are phrases we all think or hear at some point. Only fieldwork allowed me to appreciate its benefits. Parts that previously took weeks to get into production now make up in hours.

We know that the number of variables that are manipulated in the casting process are multiple and dependent on each other. From the alloy temperature, mold pH, molding time, mold position, volumetric shrinkage calculation, filter type, ambient temperature within the casting on that day or even if the operator is in a good mood at the moment of the break of a massalote, influence the quality of the piece obtained to be delivered to the client.

It is our experience as founders that allows us to balance the various variables accurately, maneuvering with skill in pursuit of the longed for perfection.

This expertise is achieved with practice, critical ability [and self-criticism, insight, patience, and above all else, wandering.

But let's face it: in a highly technological world, where response times are getting shorter, the experienced smelter, the one who looks at the color of liquid metal and knows what temperature it is, is increasingly rare. New generations of smelters can reach this level, but we need that level of knowledge and skill now, not in 15 or 20 years. This is where simulation tools such as MAGMASOFT® play an important role, narrowing the gap between the good founder and the specialist master.

Incorporating simulations into our production process with MAGMASOFT® is relatively simple: We need a digital model of the part to be cast, to know which FOSECO products use [type of sleeve, conduit, filter, etc.] and know the characteristics of the our league. With these data, we can determine the relevant characteristics of our part: whether or not there are defects and, if any, if they are within acceptable parameters, cooling and solidification times, mechanical properties, thermal stress, distortions, etc.

It is true that nothing can replace the production of a prototype to confirm that the different variables are in harmony. The fun of simulating with software like MAGMASOFT® is that this prototype will not discover and analyze the flaws the piece will have, instead it will confirm the accuracy in the calculation of our project.

Predicting results accurately reduces the costs associated with production. Most important, it helps small and medium smelters [and smelters] to be competitive against large producers.

Managing resources is critical

By captivating a customer or securing the outcome of a given process, we overestimate the parameters, which distance us from the ideal productivity costs. This increases our sales price and decreases response times, giving room for human errors and, consequently, defective parts.

The concept of quality can be defined as the ability of a product to do what it is expected to do ... and a little more. And often this "a little more" is what exclude us from the bids (processes of purchase), since prices are overestimated to ensure the outcome of our processes.

If we have the option of using the right amount of products in the casting process without compromising the qualities of the piece ... why not do it? Digital tools allow us to better manage our resources to get parts within the quality margins that our customers expect ... and on the first try! We should only ensure that the projects are executed on the "shop floor" according to the variables and conditions obtained with the digital calculation.

Renán Muñóz

Renán is a renowned metallurgical engineer in the field of national foundry.
With more than 30 years of experience and several graduate degrees in his credit, he is part of the sales team of DIPROMET, acting as a consultant in the company's various projects.