MAGMA Giessereitechnologie GmbH

Aachen, Germany

MAGMA Giessereitechnologie GmbH

Aachen, Germany
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Patent
MAGMA Giessereitechnologie GmbH | Date: 2015-07-01

A method of ray tracing by parallel computing on a computer system including a plurality of CPUs, for use in a simulation or calculation process, the method including balancing a plurality of radiation tiles between said plurality of CPUs.


A method for simulating the influence of thermally coupled surface radiation on a solid body, which solid body has at least one surface capable of being exposed to radiation, by calculating the radiative exchange between grey, diffuse surfaces, characterized in that the surface or surfaces to be exposed to radiation is/are subdivided adaptively, hierarchically into radiation tiles of the same or virtually the same radiation intensity, and the surface temperature resulting from irradiation is achieved by means of a hierarchical view factor method, which view factor method includes the evaluation of a solid angle integral using a primary solid angle subdivision, which primary solid angle subdivision has a homogeneous view factor discretization, wherein each solid angle subdivision is adaptively and hierarchically discretized into its partial areas by spherical projection and wherein the total of all partial amounts of that solid angle integral can be determined by means of ray tracing.


Grant
Agency: European Commission | Branch: FP7 | Program: CP | Phase: FoF-ICT-2011.7.1 | Award Amount: 9.30M | Year: 2012

High Pressure Die Casting (HPDC) of light alloys and Plastic Injection Molding (PIM) are two of the most representative large-scale production-line in manufacturing field, which are strategic for the EU-industry largely dominated by SMEs. Due to the high number of process variables involved and to the non-sinchronisation of the process control units, HPDC and PIM are most defect-generating and energy-consumption processes in EU industry. In both, sustainability issue imposes that machines/systems are able to efficiently and ecologically support the production with higher quality, faster delivery times, and shorter times between successive generations of products. The MUSIC is strongly aimed at leading EU-HPDC/PIM factories to cost-based competitive advantage through the necessary transition to a demand-driven industry with lower waste generation, efficiency, robustness and minimum energy consumption. The development and integration of a completely new ICT tool, based on innovative Control and Cognitive system linked to real time monitoring, that allow an active control of quality, avoiding the presence of defects or over-cost by directly acting on the process-machine variables optimization or equipment boundary conditions. The Intelligent Manufacturing approach will work at machine-mold project level to optimise/adapt the production of the specific product and can be extended at factory level to select/plan the appropriated production line. The sensors calibration and quality control of measurements will be the pre-requisite of Intelligent Sensor Network to monitor the real-time production and specific focus will be also devoted to Standardization issues. The challenge of MUSIC is to transform a production-rate-dominated manufacturing field into a quality/efficiency-driven and integration-oriented one to exploit the enormous (and still underestimated) potential of HPDC/PIM through collaborative research and technological development, along the value chain.


Thomser C.,MAGMA Giessereitechnologie GmbH | Bodenburg M.,MAGMA Giessereitechnologie GmbH | Sturm J.C.,MAGMA Giessereitechnologie GmbH
International Journal of Metalcasting | Year: 2017

The microstructure of cast iron is decisively influenced by the composition, the applied metallurgy and the process conditions. Differences in microstructure mainly influence the local mechanical properties. In conventional durability predictions, local microstructure and local defects in the casting are not taken into account. The assumption of homogeneous material properties applying one single material dataset for the prediction of fatigue strength usually leads to a misinterpretation in the assessment of local risks. Furthermore, the material potential of the casting will not be used in full. Safety margins result in an over design and unnecessarily high weight of the component as well as increased casting part costs. The designer can only benefit from the potential of the material cast iron, if the real spectrum of local material properties is considered in durability calculations. Current casting process simulation tools allow the prediction of local microstructure and resulting static mechanical properties as a function of alloy composition, applied metallurgy and local solidification and cooling conditions. Within a German research project, the link between casting process simulation and cyclic material properties was established for different cast iron materials for the first time. S-N curves (Woehler curves), which depend on local microstructure close the gap between casting process simulation and lifetime analysis. This innovative approach leads to improvements in lifetime predictions. It was shown that the consideration of local fatigue strength based on this innovative approach leads as well to an increasing number of cycles to failure as to a correct prediction of the location of crack initiation. Compared to the conventional design of castings, a substantial qualitative and quantitative improvement in assessing the real performance of cast iron materials can be realized. Copyright © 2016 American Foundry Society.


Pavlak L.,MAGMA Giessereitechnologie GmbH | Sturm J.C.,MAGMA Giessereitechnologie GmbH
International Journal of Metalcasting | Year: 2017

Oxide inclusions, which are created during the pouring process of aluminum alloys, are the main cause of leaks in castings. This contribution shows how the integration of autonomous design of experiments (DOEs) into the casting process simulation tool MAGMASOFT- provides the basis for the evaluation and subsequent optimization of process parameters in the melt transport and pouring process, which are responsible for the creation and distribution of oxide inclusions. At the same time, quality criteria describing the creation of oxides during the casting process of cylinder heads were evaluated quantitatively. The utilization of autonomous DOEs creates variations of the gating system and process parameters autonomously. It will be shown that autonomous DOEs are leading to optimized gating designs and process parameters resulting in a significant reduction of oxides in castings. The experiments supported by simulation were accompanied and validated by high-speed video technology and the PREFIL-measurement technology. Copyright © 2016 American Foundry Society.

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