Methoding magmasoft
The simulation results showed a very good match between the real defects and areas of low packing density. Having solved the curing related defects, a further core blowing analysis was carried out. Removing some of the upper and middle vents resulted in a 36% increase in the gas escaping through the lower vents. Total gas mass flow through the lower vents. Since the venting area was reduced, some filling defects were present, as expected.įigure 4. Applying these modifications, Usiminas produced another core, which did not show any gassing defects. Also, the amount of adsorbed curing gas increased in comparison to the original project.
The optimization led to a considerable increase of the curing gas concentration in the lower regions of the core (~36%) (Figure 4). However, it was clear that these changes obviously would also influence the core blowing step. Instead of making costly modifications to the core box, Usiminas determined that a possible – and simple – solution was to close some vents in the top and center regions, in order to increase the gas concentration in the bottom. The open venting cross section of the top and central vents was allowing the gas to escape before it reached the bottom of the core. The problematic area corresponds exactly with low concentrations in the simulation.Įvaluating simulated curves for the gas mass flow through the vents made it clear that the catalyzing gas was not reaching the critical area. Core Blown with new parameters in comparison with the local concentration of adsorbed curing gas. The core blowing and curing steps for the PU coldbox process were analyzed, making it possible to draw preliminary conclusions regarding the existing defects.įigure 3. This core, called the thin waist core, represents some of the biggest challenges for Usiminas core production: its length (920 mm), substantial changes in the sand flow direction during blowing, the need to fill certain parts of the core through counter-flow and big variations in the cross section within the core.įirst trials showed problems with the process, which led to a complete collapse of the lower part of the core. The main goal was to optimize the process conditions for the existing tooling layout.
METHODING MAGMASOFT SOFTWARE
The first project on which this software was utilized was already in progress at that time. The bottom of the core collapsed due to a lack of strength.īrazilian steel giant Usiminas recently introduced the new foundry core making simulation software MAGMASOFT® as part of their strategy to establish robust designs and processes for their core production line. The current advantages, such as minimum footprint area, smallest contact area and optimum moulding sand compaction beneath were adopted from the existing FEEDEX K concept.Figure 1. The self-centring FEEDEX VAK Feeder sleeves are designed for ram-up applications in greensand moulding lines.
SCK provides flexibility, feeding efficiency and small contact areas, thereby optimising yield and casting cleaning costs. The glue-free, easy-to-assemble range of 6 elements provides 16 options with Modulus values between 5.4cm to 6.9cm for precision feeding in large castings. The SCK Sleeve system is an innovative, hybrid insulating/ exothermic, modular Sleeve Construction Kit (SCK) for iron and steel jobbing foundries.
METHODING MAGMASOFT PRO
New additions to the Foseco sleeve product range, such as FEEDEX VAK and the SCK sleeve system, will be made available in an upcoming release of the Pro Module for use in method analysis and optimisation work. Simulation with MAGMASOFT® also plays an important role in virtual experimentation and new sleeve development.