For the Brazilian faucet and shower specialist Docol, sustainability is an integral part of their corporate policy. Their measures aim at reducing raw material and energy consumption, as well as minimizing environmental impact. To actively contribute to environmental protection in this area, the company decided to use numerical simulation with MAGMASOFT®.
The following example shows how virtual simulation enabled Docol to reduce the scrap rate in the production of a one-handle faucet. Figure 1a shows the “Lift” mixer, whose body is cast from a copper-zinc alloy asa low-pressure die casting. The cast part systematically showed hot tears in the rear area, which affected the surface of the part (Fig. 1c). Hot tears occur at the end of solidification, usually run along grain boundaries, and the fracture surface is intercrystalline. This formation mechanism can often be recognized from the shape of the crack, which is “jagged” in the finished part (Fig. 1d).