![magmasoft crack and distortion magmasoft crack and distortion](https://www.magmasoft.com/export/shared/.galleries/solutions/MAGMA5_c-pic07_800x400.jpg)
In addition, the yield was only about 49 %. The filling pattern also led to a hotspot and a shrinkage defect in the bottom of the casting. The top ingate was filled too quickly, and this caused casting defects due to turbulence and a large amount of entrapped air. The original design of the gating system of the front fork led to several problems that were detected by simulation. The original gating system of a front fork component led to problems that were analyzed using MAGMASOFT ®. This approach leads to an optimized design and casting process of the engine block. To avoid problems, a manufacturing process simulation can be performed at an early stage of the design process, where geometric or casting process modifications may be made to decrease the level of tensile stresses. The biggest influences on residual stresses in castings are the design (80%) and the casting process itself (20%). One can try to use compressive stresses as a pre-loading, like in pre-tensioned concrete. It is unusual that compressive stresses are critical. Nevertheless, even if tensile stresses are below the critical value, the casting may fail during assembly, or even worse during driving.Ĭompressive stresses are the opposite of tensile stresses and are those stresses that are induced by pushing. As a rule, tensile residual stresses are lower than this threshold value and the casting does not fail during the casting process. By reaching this value, cracking occurs and the part fails.
![magmasoft crack and distortion magmasoft crack and distortion](https://www.inas.ro/assets/images/1/magma-non-ferrous-3-0eb283b1.png)
Tensile stresses, those stresses that are induced by “pulling”, may be critical during the manufacturing process, if their value exceeds the material’s tensile strength. Residual stresses develop during solidification and cooling of the casting due to uneven cooling rates in the different wall thicknesses. Only by using manufacturing process simulation, is it possible to determine the distribution of residual stresses in castings and to consider these properties in the design optimization process. Their performance and weight are, among other criteria, dependent on their geometry and the casting process, especially defects like porosity and residual stresses. Cast iron engine blocks can be found in more than half of all passenger cars.