Queen's Award for Enterprise

Casting Simulation and Magma

In the past the traditional approach to casting development was by largely trial and error. This would involve producing a casting gating system by a foundry engineer’s best estimate, then if this failed, a second, third etc version would be produced until a satisfactory casting was achieved. This approach was both costly and time consuming, resulting in longer project lead times and expensive parts.

At Grainger & Worrall the decision was taken to introduce casting simulation as an imperative tool to run virtual casting trials on a computer, and thereby remove the need to produce multi-casting trials in the foundry.

Information obtained via casting simulation can then be used to refine the casting method before a “real” trial is carried out in the foundry.
Casting Simulation and Magma Philosophy The goal of casting simulation is to produce a part “right first time” without the time and expense of multiple founding trials. This is achieved by working in partnership with our customers, and using Magma simulation to develop a robust manufacturing method before the first mould is poured. In addition to this, various alloys can be trialled in a virtual environment to optimise structure and properties by utilising the ‘Magma Iron’ module for casting and ‘Magma Non-Ferrous’ for aluminium castings.

This data is then used in conjunction with our customer’s requirements to maximise properties in the finished component.
Magma simulation also offers an insight in to the residual stress levels in the as cast condition and after heat treatment. This data can then be used to support customer finite element analysis.

Casting Simulation and Magma Expertise
Grainger & Worrall has experience of over 500 simulation projects ranging from high specification motorsport to commercial automotive components in Grey, SG, and Compact Graphite Irons, to various aluminium alloys.

All casting simulation predictions are validated by X-Ray, Computerised Tomography (CT), micro examination, and tensile testing. This results in continuous improvements in the accuracy of virtual results obtained by the Magma simulation.

Grainger & Worrall have extensive experience in the following casting simulation areas:

Magma Iron – Structure and properties predictions for iron castings.
Magma Non-Ferrous – Structure and properties predictions for aluminium castings.
Magma Stress – Residual Stress predictions in the as cast condition.

Magma Heat Treatment Stress – Residual Stress prediction during and after heat treatment.
Magma Rollover – to support the casting produced using the roll over (Cosworth) process.

Magma Link – To support mechanical properties data export to third party analysis systems such as Abaqus, Ansys etc.