Simulation and Engineering Services with MAGMASOFT®
A Better Understanding of Casting. More Confident Process Decisions.
As a partner of MAGMA GmbH, EXOTERM-IT combines casting simulation with practical knowledge of foundry processes and materials. We provide simulation and engineering support to foundries in the countries of the former Yugoslavia. Using MAGMASOFT®, we help you evaluate process designs, investigate the causes of defects and identify opportunities to improve casting quality and yield.
Our simulation support is tailored to your challenge — from evaluating an individual solution to supporting the development and improvement of your production process.
What Challenges Can We Help You Address?
Evaluating New Castings and Process Designs
We evaluate the proposed design before tooling is manufactured or the first casting trial is carried out. Simulation helps identify critical areas and compare potential adjustments to the geometry and casting process.
Mould Filling, Solidification and Feeding
We analyse molten metal flow, temperature distribution and solidification behaviour. We assess the gating and feeding system design and explore opportunities to reduce the risk of incomplete filling and shrinkage defects.
Investigating Production Defects
We compare simulation results with observed defects and available production data. This helps us investigate potential causes and propose changes for validation in production.
Comparing Process Alternatives
We evaluate the effects of selected changes, such as pouring temperature and pouring time, feeder placement or cooling strategy. Comparing alternatives helps identify a solution that meets your quality requirements and production constraints.
Improving Casting Yield and Material Efficiency
We investigate opportunities to improve feeding efficiency and reduce the amount of metal in the gating and feeding system. The objective is to improve casting yield while maintaining the required casting quality.
Advanced Simulation and Optimisation Services
Stress and Deformation Analysis
We analyse the development and distribution of residual stresses and casting deformation during cooling. By comparing process alternatives, we explore opportunities to improve dimensional stability and reduce the risk of cracking.
Heat Treatment Simulation
We investigate how heating, soaking and cooling affect the temperature distribution within a casting. Depending on the material and the objectives of the analysis, we also assess microstructural evolution, mechanical properties, residual stresses and deformation. Comparing heat treatment cycles helps achieve the required properties, shorten treatment times and reduce the risk of dimensional deviations.
Virtual Design of Experiments (DoE)
Through planned simulation studies, we systematically evaluate the effects of selected process parameters and their interactions. This enables us to identify the factors with the greatest influence on the outcome and define a process window in which the required quality can be achieved consistently.
Autonomous Optimisation
Based on agreed objectives and constraints, the software automatically explores and evaluates alternative geometries and process parameters. Multiple objectives can be considered simultaneously, such as reducing defects and deformation while improving casting yield. We assess the results and prepare recommendations for implementation in production.
How Does the Collaboration Work?
Define objectives
Together, we identify the problem, desired improvements and comparison criteria.
Prepare data
We review the geometry, material, production process and available production results.
Simulate and assess
We analyse the baseline conditions and agreed alternatives.
Report and recommend
We present the key findings, compare solutions and recommend next steps.
Support Tailored to Your Project
We can work with you on an individual project or provide additional support to your process engineering or development team. The scope of analysis and collaboration is tailored to your process, available data and objectives.
Let’s Discuss Your Challenge
Are you developing a new casting, resolving defects or looking to improve casting yield? Send us a brief description of your task, available drawings or a 3D model, and basic process information. Based on this information, we will propose a suitable scope for the simulation study.