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.