Simulation software helps boost foundries’ bottom line

In general, foundries effectively recycle their materials. More than 90% of all cast parts in Germany are made from remelted scrap metal. And the reuse of molding materials such as sand and water means almost no waste.

However, foundries spend a lot on energy and materials — on average 40% of all costs. Physical laws dictate that an average energy input of 2,000 kW-hr per metric ton of final casting product is needed. This adds up to a total energy consumption of 11 billion kW-hr in the German foundry industry per year. Over 50% of this energy is used just to fill gates and risers.

Fortunately, casting-simulation software helps foundry engineers optimize casting parameters, often before the first part is poured. Simulation helps to minimize the amount of material cast and, thereby, the amount of energy needed for the melting process.

Simulation also plays a role in cutting CO2 emissions by helping users slash process and cycle times for high-production castings. Engineers can use simulation to optimize heat-up and temperature distribution in permanent molds, plan layouts that maximize the number of parts molded at one time, and reduce or eliminate preproduction trial-and-error runs.

Here are a few example of how simulation software such as Magmasoft can help optimize casting operations.