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Background Triumph UK began started outsourcing since 1980s.

One of their primary concern would the local manufacturers out in Asia will be able to meet their critical surface requirement which we can see evident in all of their bikes.

Triumph UK have been making use of MAGMA Gmbhproject services for many years now, and confident that these services is also readily available in MAGMA Asia Pacific, who is responsible for the development of 3 casting components with local captive die caster in West Malaysia.

The flow and solidification simulation should help to detect the failure formation and to provide a basis for optimization measurements

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Complete shot and final version

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Cam Cover - AluminiumCasting Geometry and Cooling System

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Process Route, Simulation Setup

Alloy: ADC 12 (AlSi10Mg) Die material: SKD 61(~X20Cr13) Initial temperatures:

Die: 220 C Melt: 680 C coolant (oil): 180 C spray (water): 20 C

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Casting /Process Parameters

Casting weight: 1028 g. Shot weight: 2017 g Plunger Diameter: 90 mm Filling time: 30 ms Gate velocity: 31 m/s Flow rate: 12723 cm3/s Filling pressure: 135 bar Intensification: 550 tons Machine : Buhler H-400B 1st Phase Speed: 0.25 m/sec 2nd Phase Speed: 2.00 m/sec 2nd Phase Switch: 295.00 mm

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Cam Cover - AluminiumTime to fill a certain region

Last sections to be filled

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Fill time plot, critical area

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Cam Cover - CastingSimulation vs Reality Check

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Shifted the position of Spot cooling up problemresolve

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Summary

The flow analysis did found the casting sections that are critical for cold shuts and air entrapments due to insufficient venting.

The flow analysis provides the information about the flow pattern of the melt

This is the basis for die optimization measurements such as repositioning of the overflows and modification of the spot cooling lines.

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Background One of the primary quality requirements

of this component is the surface quality finish as the casting will undergo secondary plating flow mark, cold shuts cannot be tolerated.

Magma tracer and filltime filling criterion is use extensively to analyze the flow and make changes to gating system to improve flow characteristics.

The flow and solidification simulation should help to detect the failure formation and to provide a basis for optimization measurements

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Casting Final Version

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Aluminum Clutch CoverCasting Geometry and Cooling System

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Process Route, Simulation Setup

Alloy: ADC 12 (AlSi10Mg) Die material: SKD 61(~X20Cr13) Initial temperatures:

Die: 200 C Melt: 680 C spray (water): 28 C

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Casting /Process Parameters Casting weight: 2177 g. Shot weight: 4270 g Plunger Diameter: 120 mm Filling time: 25 ms Gate velocity: 54.5 m/s Flow rate: 39584 cm3/s Filling pressure: 135 bar Intensification: 700 tons Machine : Buhler SC_D140 1st phase Speed: 0.25 m/sec 2nd phase Speed: 3.50 m/sec 2nd Phase Switch: 700.00 mm

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Time to fill a certain regionAluminum Clutch Cover

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Filltime Checking surface flow lines/flow marks

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Summary The flow marks was successfully

rectified through the modification of ingate thickness to control flow rate through each gate/

The flow analysis help us detect flow lamination effect, that assist us to resolve secondary peeling effect after shot blasting.

This is the basis for die optimization measurements such as repositioning of cooling lines.

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Background One of the primary quality requirements

of this component is the surface quality finish as the casting will undergo secondary plating flow mark, cold shuts cannot be tolerated.

Magma tracer and filltime filling criterion is use extensively to analyze the flow and make changes to gating system to improve flow characteristics.

The flow and solidification simulation should help to detect the failure formation and to provide a basis for optimization measurements

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Finish Casting Picture

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Aluminum RH Cover Aluminum RH Cover Geometry Layout Geometry Layout with with cooling channelscooling channels

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Process Route, Simulation Setup

Alloy: ADC 12 (AlSi10Mg) Die material: SKD 61(~X20Cr13) Initial temperatures:

Die: 220 C Melt: 675 C spray (water): 28 C

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Casting /Process Parameters Casting weight: 996 g. Shot weight: 2178 g Plunger Diameter: 90 mm Filling time: 27 ms Gate velocity: 32.8m/s Flow rate: 15904 cm3/s Filling pressure: 135 bar Intensification: 700 tons Machine : Toshiba DC350CL 1st phase Speed: 0.25 m/sec 2nd phase Speed: 2.25 m/sec 2nd Phase Switch: 340.00mm

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Filltime Filltime Result Result Time to fill the cavityTime to fill the cavity

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Possible Shrinkage

Late solidificationAround bearing hsg

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Summary

The flow analysis did found the casting sections that are critical for cold shuts and air entrapments due to insufficient venting.

The flow analysis provides the information about the flow pattern of the melt

This is the basis for die optimization measurements such as repositioning of the overflows and modification of the gating system

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Thank very much for listening

BackgroundComplete shot and final versionCam Cover - AluminiumCasting Geometry and Cooling SystemProcess Route, Simulation SetupCasting /Process ParametersCam Cover - AluminiumTime to fill a certain regionFill time plot, critical areaCam Cover - CastingSimulation vs Reality CheckCritical areas for feedingSummaryBackgroundCasting Final VersionProcess Route, Simulation SetupCasting /Process ParametersSummaryBackgroundProcess Route, Simulation SetupCasting /Process ParametersSummary