The constitutive model and fracture criterion are calibrated both with data from material tests and data from the process simulation using MAGMAsoft. The fracture criterion is coupled with an element erosion algorithm available in LS-DYNA. The cast magnesium alloy is modelled using a user-defined material model consisting of an elasticвЂ“plastic model based on a modified J2-flow theory and the CockcroftвЂ“Latham fracture criterion. The experimental data are applied to obtain a validated methodology for finite element modelling of thin-walled cast components subjected to quasi-static loading. In this work, generic High Pressure Die Cast (HPDC) AM60 components have been studied using axial crushing, 3-point bending and 4-point bending tests. The methodology consists of casting process simulations using MAGMAsoft, mapping of data from the process simulation onto a FE-mesh (shell elements) and numerical simulations using the explicit FE-code LS-DYNA. 'The user-friendly integration of our data in MAGMASOFT is thus decisive for the quality of planning.A through-process methodology for numerical simulations of the structural behaviour of thin-walled cast magnesium components is presented. Even if being mostly applied to multistep processes, single process steps may be so complex by nature that the needed models to describe them must include multiphysics. Comprehensive customer service therefore already has the highest priority for us in the planning stage of production processes,' confirms JГ¶rg Brotzki, Executive Vice President Europe at ASK Chemicals. Numerical modelling is increasingly supporting the analysis and optimization of manufacturing processes in the production industry. 'With the possibility to predict the behavior of our products with any core geometries during casting, we can support our customers in a more targeted manner. New Low-Formaldehyde System For Cold Box Production 'We are pleased to have gained a competent development partner with ASK Chemicals, who are interested in quantifying the behavior of their binder systems during casting.' The possibility of systematically avoiding core gas-related casting defects through quantitative consideration of different ASK binder systems already at the project planning stage represents a significant benefit for our customers,' confirms Dr.-Ing. 'For MAGMA, this project is an important step in the direction of 'robust process design for casting technology'. Product-dependent kinetic models will be derived from these data that will make the formation of gas volumes and the resulting effects in MAGMASOFT quantitatively predictable. Respective laws of decomposition behavior and resulting gas formation will be quantitatively determined for different binder systems and heating characteristics. To this end, ASK Chemicals will carry out extensive research in their laboratories and Technical Center. The availability of practical quantitative data already during simulation-based design of castings and cores therefore contributes significantly to the prevention of defects.ДЄSK Chemicals and MAGMA have agreed on a collaboration as part of a development project to quantify the decomposition behavior and gas formation of different ASK binder systems. This functionality enables accurate prediction of the risk of defects due to gases from cores and molds.

Newly developed simulation models in MAGMASOFT virtually depict gas formation, gas flow, and venting through core prints or the penetration into the melt.

Magmasoft modelling