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Committed to Casting Excellence

04/18/08

MAGMAhpdcGating Geometry

Optimization

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OriginalDesign

The originalfilling pattern is

shown. The marked side

of the gate fillsthe casting all

around and thenback fills thecasting cavitywith the lastpoint of fill in

the centre of thecasting.

This results inhigh air pressure

in the castingcavity.

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OriginalDesign

The airentrapment and

air pressure forthe originalfilling patternare shown.

Air Entrapment

Air Pressure

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Optimization

The objective ofthe optimizationwas to minimizethe maximum airpressure and theaverage airpressure in thecasting cavity.

The gating design

parameters havebeen varied withthe definedconstraints toobtain the optimal

design. The points in the

plot shows thedesigns and themarked points arethe optimizeddesign withreduced air

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Modified

Design

The modifiedgating design

created byMAGMAfrontier is shown.

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AirEntrapment

MAGMAfrontier has

automaticallyreduced the airentrapment forthe design(optimized)

shown.

Air Entrapment withoptimized design

Air Entrapment withoriginal design

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AirPressure

The uniformfilling pattern

created byMAGMAfrontier through thecasting cavityallows the air

to escapethrough theventedoverflows.

The airpressure hasbeen reducedby 100% and is

nowacceptable.

Air Pressure withoptimized design

Air Pressure withoriginal design

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Conclusions and Recommendations

The objective of the optimization was to minimize themaximum air pressure and the average air pressure in thecasting cavity.

The gating design parameters have been varied with constraintsto obtain the objective.

The filling pattern obtained with the optimized gating design isuniform with last point of fill at the overflows.

The air pressure has been reduced significantly with theoptimized design.

The air entrapment in the casting cavity has been reduced and isnow acceptable.