SAEN Designs and Builds Die Casting and Trimming Tools with MAGMA5

SAEN is a well-known Italian toolmaker serving the European and international foundry industries with high quality die casting tools. The company uses the latest technology and provides comprehensive services ranging from structural analysis, casting process simulation with MAGMA  5 up to in-house prototyping.

Using an entire palette of virtual and real technologies, SAEN is able to cut the development and release times for its tooling production drastically. Furthermore, the company enhances its casting know-how through testing and verifying on its own all of the technical solutions that are proposed through the use of these tools. For this reason, the company is also equipped with two die casting machines allowing them to do sampling for all the tooling they manufacture.

The component designer also benefits from this approach, as he profits from the die caster’s point of view and in-depth knowledge of the needs of the die casting process during the design process.

In the foundry, SAEN’s new tooling is sampled using simulation results as a basis. If necessary, several iterations of simulations in MAGMA5 are used to determine robust process conditions, which are then used to cast samples that can be tested and employed by the final customer. The simulation data and results are also checked through an analysis of the cast components and through filling tests carried out in the foundry. A comparison with different component sections or X-ray images is used.

Defect prediction from a MAGMA5 simulation (left), x-ray inspection (center), as-cast result (right)

The foundry gathers extensive empirical data during sampling and reports them to the customer. This allows the customer to employ parameters which have been effectively verified when starting series production. These data are also sent back to the technical and simulation department so that, in the case of a replacement tool, they can take advantage of both the simulation results and the foundry’s experience to plan the manufacture of new tooling.

Machined part (left), critical area for leakage shown during solidification (right)

During the simulation phase, the feeding system design is developed using the solidification results as a basis, also considering the technical limitations presented by die movement during ejection and trimming.

Through various discussions with the customer, the layout of the tool and of the ingates is optimized, leading to a solution that guarantees the best results before continuing with the final tool design and manufacture. This positive loop, which is fostered by both the company’s and the customer’s direct experience, makes continuous improvements and a constant evolution in technical skills and proficiency in tooling manufacturing possible.

Optimized pattern and inserts without cooling lines

Today, when specialized casting skills and knowledge are often not available even in large companies in the automotive industry, the possibility of finding them all gathered in one single partner represents a strong competitive advantage. SAEN is committed to a further development of this advantage into the future.

A significant benefit is provided by the thermal analysis, which allows the efficiency of the temperature control systems to be checked. In this way, the required high quality standards such as minimized cycle times, reduced maintenance effort and dimensional compliance of the cast part can be guaranteed.

In the example shown, it is possible to see how the thermal balance as well as local temperatures in the die casting tooling can be controlled by introducing an optimized thermal regulation system focused on critical areas in both the tool and the cast part.

In a similar way, it is possible to check the diameter of the cooling lines and the effects of cooling medium flow rates in advance, in order to ensure a balanced removal of heat throughout the die.


About SAEN

Located in the south of Padova in Italy, SAEN started its activities in 1971. Since then, it has worked exclusively in the field of die casting. SAEN has a highly motivated staff of 85 people, of which 35 work in the design and technical department. 95% of the production is exported with 80% staying in Europe and 15% going to the USA.

Over the years, the company has increased its expertise in providing its customers with 2D and 3D measurement reports, sampling, machined prototypes, casting process simulation carried out with MAGMASOFT® and casting structural analysis with ANSYS. SAEN has also taken part in European projects directed at research and development issues.