MAGMA üniversiteler ve enstitüler ile işbirliklerine büyük önem vermekte olup; birçok ulusal ve uluslararası araştırma projesinde aktif olarak yer almaktadır.
Ar&Ge Çalışmaları
Ortak Projeler
Seçilen Projelerin Gelişim Aşamaları
DNAguss: Consistent numerical design of cast components along the process chain
The aim of MAGMA in this R&D project is the state-of-the-art integration of the casting process simulation into the virtual process chain for the numerical design of cast components.
For this integration, the connection between the CAE technologies used in construction and shape optimization and the casting process simulation on the one hand, the casting process simulation and the CAE technologies used for component evaluation and design on the other hand, and finally the casting process simulation and the non-destructive testing methods used in casting testing should be improved.
The knowledge gained from the planned "DNAguss" project will enable the state-of-the-art integration of the casting process simulation into the virtual process chain for the numerical design of cast components in order to ultimately create a digital twin of the casting manufacturing process that is integrated into the entire virtual process chain realize.
German foundries of large castings, in particular castings for wind energy and their customers, are enabled to make their production and quality assurance processes more efficient, more energy-saving and more economical. In this way, the foundries can hold their own against international competition, which is achieved not least through the increased scope of testing and evaluation options for the purchaser of the cast components. In particular, the work in the field of non-destructive testing for the detection of casting defects and the work of MAGMA on casting simulation ensure that the project results are implemented directly in practice.
Key facts of the project:
Project duration: 01.01.2020 - 31.12.2022
Project Management: Fraunhofer-Institut für Betriebsfestigkeit and Systemzuverlässigkeit (LBF) in Darmstadt
Consortium: Fraunhofer-Institute LBF (Darmstadt), IKTS (Dresden), Univerity Ansbach
Associated: INTES (Stuttgart), MATPLUS (Wuppertal), BMB (Heilbronn), MAGNA (St. Valentin, Österreich), HEGER (Enkenbach-Alsenborn) and Meuselwitz
Project promoter: DNAguss is funded by the Federal Ministry for Economic Affairs and Energy, via the Project Management Organisation Jülich, Forschungszentrum Jülich GmbH, under the funding code 03EE3018C.
GrenzQualifizierung is the short title of the project ”Rechnergestützte Beurteilung der Bauteilfestigkeiten auf Basis virtueller Grenzmuster” (Computer-assisted assessment of component strength on the basis of virtual limiting samples).
Large castings made of spheroidal graphite iron (SG) offer indispensable advantages for the wind energy sector as well as for the construction of large machines and plants due to the high degree of creative freedom and the low manufacturing costs. The increase in performance of plants with simultaneous resource-saving processing requires increased material utilization and places special demands on the knowledge of cyclic material behavior. In this context, there have always been large gaps in the linking of casting simulation, construction, fatigue design measurement and nondestructive quality assurance concerning the design, construction, dimensioning and quality assurance especially of thick-walled components.
Since inside the casting the occurrence of imperfections such as discontinuities (e.g. dross, blowholes) and microstructure degenerations such as chunky graphite cannot be ruled out due to the manufacturing process, tools are required that allow fast and documented decisions whether and where these imperfections are permissible in the component. Taking into account component-specific stress situations, down to the present day there is a lack of options to precisely describe the effect of the found imperfections on the structural durability of large cast components.
The GrenzQualifizierung project is working on the development of such a method to derive virtual limiting samples for practical application. The virtual limiting sample indicates permissible defects for all component areas depending on the local load and the service life requirements. As information on locally permissible imperfections is already stored in the virtual limiting sample, a significantly simplified test procedure can be used for quality assurance and a reliable decision can be made as to whether or not a component is to be rejected. To this end, casting simulations, component dimensioning and nondestructive quality assurance have to be digitally cross-linked in the sense of Industry 4.0.
The project focusses on the microstructure degeneration of chunky graphite as well as the ”dross” discontinuity in different casting materials (EN-GJS-700-2, EN-GJS-400-18, EN-GJS-450-18, EN-GJS-1050-6 (ADI)) including their effect on the local vibration strength. For this purpose, Fraunhofer IZFP is developing a method to detect chunky graphite on both, test specimens and real components using magnetic and acoustic nondestructive testing methods. Furthermore, methods are evaluated to assess the nodularity of spheroidal graphite.
Key facts of the project:
Project duration: 01.07.2018 - 30.06.2021
Funding body: BMWi (PtJ)
Consortium: ACS Solutions GmbH, BMB Gesellschaft für Materialprüfung GmbH, Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF (Koordinator), Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP, Siempelkamp Gießerei GmbH, Meuselwitz Guss - Eisengießerei GmbH, ZF Wind Power Technology, ZWP Anlagenrevision GmbH, Eickhoff Gießerei GmbH and MAGMA Gießereitechnologie GmbH
Project promoter: PTJ, Jülich
Image source: Fraunhofer LBF
MaBIFF: "Dimension-reduced component properties through the integration of production and functional simulation"
The aim of the research project MaBiFF was to assess the influence of different microstructural features in cast iron (GJS-400 and GJV-450), which can be locally predicted using casting process simulation, on durability. For this purpose, S-N curves were determined for varying microstructures from extensive tests, enabling the creation of a closed chain considering the manufacturing parameters through the calculated local microstructures up to a prediction of the local durability. This makes the transfer of the influence of the manufacturing process in operational fatigue calculations possible.
Within the scope of the MaBIFF project, the prediction of local microstructures was extended. For this purpose, MAGMA developed a calculation procedure in which process simulation was integrated into computational fatigue calculations. A correlation between the local durability and the local microstructure was determined. In addition, the necessary interfaces for data exchange with programs for fatigue life calculation (for example, FEMFAT, LMS Virtual Lab Durability) were created. This makes it possible to calculate the expected durability for the materials GJS-400 and GJV-450 based on a casting simulation and to transfer this information as input for durability calculations.
This research and development project was funded by the Federal Ministry of Education and Research (BMBF) under the funding code 01RI0713 and was supervised by the German Aerospace Center (DLR) in Bonn. The project was carried out as a joint project between 01.08.2007 and 31.03.2011.
Project partners in this project were Audi AG, Eisenwerk Brühl GmbH, Meuselwitz Guss GmbH and Walter Hundhausen GmbH, Fraunhofer Institute for Operational Strength and System Reliability LBF, Fraunhofer Institute for Technological and Economic Mathematics ITWM, Germanischer Lloyd Industrial Services GmbH, Institute of Foundry Technology IFG and MAGMA Gießereitechnologie GmbH .
A detailed project summary can be found here: Bundesministerium für Bildung und Forschung.
MAGMA, 17-18 Eylül 2012 tarihlerinde MUSIC kısaltması verilen “MUlti-layer control&cognitive System to drive metal and plastic production line for Injected Components (Enjekte parçalar için metal ve plastik üretim hatlarında çok katmanlı kontrol ve kavramsal sistemler)” isimli projenin Vicenza, İtalya’da gerçekleştirilen başlangıc toplantısında yer aldı. 4 yıl sürecek ve 15 ortağı (EnginSoft SpA (proje koordinatoru), Aalen Üniversitesi, Ascamm Teknoloji Merkezi, AUDI AG, Electronics GmbH, Oskar Frech GmbH +Co. KG, Fraunhofer IFAM, Maier S. Coop., Motul SA, Padova Üniversitesi, rds Moulding Technology SpA, Regloplas AG, Fundacion TEKNİKER, Toolcast snc, ve ASSOMET Servisi) bulunan proje kısmi olarak Avrupa Komisyonu tarafından finanse ediliyor.
Projenin amacı, döküm ve plastik enjeksiyon için gerçek zamanlı proses izleme ile bağlantılı olan, aktif bir kalite kontrolü sağlayan ve proses değişkenlerine direkt müdahale imkanı ile hataların giderilmesine imkan tanıyan inovatif bir kontrol ve kavrama sistemi geliştirmektir. Bu akıllı üretim yaklaşımı, üretim verilerinin toplanması ve değerlendirilmesi ile üretim hücresinin optimize edilmesi için makine-kalıp düzeyinde çalışacak. Akıllı bir sensor ağı, farklı sensor ve ekipmanlardan eş zamanlı olarak bilgi toplayarak üretim parametrelerini gerçek zamanlı olarak izleyecek. Geliştirilmiş bir meta model, girdi parametrelerini ve sensor verilerini kalite endeksleri, enerji tüketimi ve maliyetler ile ilişkilendirecek.
Gelişmiş proses simülasyonu, veri yönetimi ve meta model üretim verimliliğini geliştirecek olan kavramsal sistemin elde edilmesi aşamasında önemli faktörler olarak ön plana çıkıyor. MUSIC projesinin sonunda ulaşılması hedeflenen nokta ise, düşük ağırlıklı alaşımların yüksek basınçlı dökümü ve polimerlerin enjeksiyonla kalıplanması gibi geleneksel üretim sektörlerinin yerini hatasız üretim, enerji verimliliği yüksek ve maliyetlerin düşük olduğu akıllı üretim sistemlerine bırakmasını sağlayabilmek.
Daha fazla bilgi için : http://music.eucoord.com
EffSAFound2 – Demir ve Çelik Dökümhanelerinde Enerji ve Malzeme Verimliliği
Güney Afrikalı dökümhanelerde enerji ve malzeme verimliliğini geliştirmek için Eğitim ve Araştırma Alman Federal Bakanlığının (BMBF) desteklediği CLIENT araştırma girişimi "EffSAFound2" başarıyla tamamlandı. Projede, Alman ve Güney Afrikalı partnerler sekiz Güney Afrikalı demir ve çelik dökümhanesiyle birlikte 30 ay boyunca ortak çalıştı.
Proje kapsamında, yüksek kromlu beyaz demir için kapsamlı malzeme verileri MAGMA5 içerisinde ölçüldü ve uygulandı. Dökümhanelerdeki gelişmiş enerji verimliliği ve kaynak kullanımı talebini karşılamak için son döküm projelerine dayanan referans örnekler MAGMA5 kullanılarak optimize edildi.
11 resmi dil konuşulması ve çalışan niteliklerinin çeşitliliği sebebiyle döküm prosesleri ve makine operasyonlarına yönelik bilgi ve beceri transferine Güney Afrika’da özellikle ihtiyaç duyulmakta. Bu prosesi daha iyi desteklemek için, hg.visutec from HegerPro yazılımının İngilizce bir versiyonu da artık mevcut. Sağlanmış olan multimedya içeriği çalışanların farkındalığını yükseltmeye ve çalışma rutinlerini optimize etmeye yardımcı olacaktır.
Ek olarak, dökümhaneler kum yönetimini başarıyla geliştirmişlerdir. Alman firması GUT (Gießerei-Umwelt-Technik) tarafından atık kumun organik içeriğinin kontrol edilmesi için bir prosedür geliştirilmiş ve tesis içerisine adapte edilmiştir. Modüler termal ve mekanik kum rejenerasyonu için merkez tesis ise gelişme aşamasındadır.
Proje kapsamında, Ametex, MAGMA’nın Güney Afrikalı ortağı, katılımcı dökümhanelerdeki döküm kalitesini iyileştirmek amacıyla MAGMASOFT® kullanımı konusunda öğrencilere eğitim vermiştir.
Efficient process chains for aluminum die casting
The aim of the joint project was to increase the utilization efficiency of energy and resources in the aluminum die casting process chain. The focus of the project was the overall process chain from melting the starting material through the actual casting process, an alloy-dependent heat treatment and machining to the product in the required final quality.
MAGMA has played a central role in the project, since the simulation of the die-casting process can be used to determine and verify decisive measures to increase the utilization efficiency of energy and resources. For this purpose, MAGMA systematically applied MAGMA’s process optimization capabilities in die casting. The focus of the investigations was the reduction of volume or return material, the minimization of the cycle times, the setting of an optimal spraying process and the increase of tooling life. For this purpose, heat transfer coefficients were also determined on a test stand.
The project was selected by independent experts as part of the BMBF framework "Research for the production of tomorrow" within the "innovation resource efficiency" of the ideas contest "Improving energy efficiency in production technology".
The project was carried out between 01.06.2009 and 31.08.2012.
