The Silbitz Group GmbH manufactures complex and highly stressed cast parts. For this reason we have now been using the simulation programme from MAGMA for more than 10 years as an aid in the creation of our casting technology.
The basis for the simulation is the 3D CAD model of the cast part. This can be created with the help of the CAD programmes CATIA V5 Solidworks or Mechanical Desktop.
Using the solidifying simulation for the cast part the position and size of the hot-spots is illustrated. Using this as a starting point for the subsequent calculations in the simulation model the cooler ingot moulds and the various risers can be positioned. Thus the occurence of porosities (for example shrinkage cavities) in cast steel and cast iron can be recognised. In addition a function is available for cast steel that indicates the so-called centre line defects. For the fundamental understanding of the results calculated, a view of the progressive solidification in the system cast piece / casting technology is helpful.
The simulation of the mould filling, which must be even without turbulences, enables the gating system to be checked. Here defects such as impurities in the cast iron, for example dross, or the formation of oxide in cast steel can be minimised or, if possible, avoided.
With the simulation of the internal stresses for cast steel as well as cast iron the state of the stresses in the cast part after casting and cooling can be calculated. If it is necessary to subject the cast part to be manufactured to a heat treatment, the state of the stresses changes again and can then no longer be simulated.
The use of the simulation programme from MAGMA, together with our longstanding experience helps to successfully manufacture cast parts with a reliable and optimised casting technology right from the very first cast. Thus we can, in the interests of our customers, manufacture in the required quality at calculable costs.