As a result of this and further successful validation efforts, this new time-dependent plasticity model will be made publicly available in MAGMA5 Rel. This was a key to success, as MDT found that the stress levels actually observed were predictable with MAGMASOFT® when considering creep effects occurring during the slow cooling of the casting in the mold. In this context, MDT and MAGMA worked together to verify new capabilities of a visco-elasto-plastic material model for MAGMAstress. This approach is well suited for materials with coarse structures, such as cast iron. In order to ensure that the residual stress results from MAGMASOFT® give the correct picture of the stress situation, MDT initially performed residual stress measurements on actual cylinder frames using the ring core measurement method. To identify the endangered areas and validate design and process changes, MDT uses MAGMASOFT®. The functionality dictates the geometry and requires changing wall-thicknesses, sometimes leading to crucial stress situations. These frames are sand cast in GJL-250 gray iron or GJS-500 ductile iron and weigh up to 40 tons. This is a problem that MDT quality management is eager to avoid before it occurs, as the fallout is very hard to deal with.Īn example for this are the cylinder frames for the two-strike-engines. In some cases and under certain conditions, residual stresses can sum up to problematic amounts and result in a shortened engine lifetime. To ensure longevity, MDT is always looking to minimize residual stresses in the component. This marks them as being known to carry an important function and to present manufacturing challenges, often with regard to castability and durability. Many of the cast parts are classified as a “controlled component”. Materials range from steel to CGI, providing the required material properties such as sufficient strength and good heat transfer. Roughly 30% of the mass of a two-stroke engine is made of cast components, and on the smaller bore four-stroke engines, the entire frame structure is cast in one piece. The component list of a diesel engine includes a large number and variety of castings such as liners, bearing caps and cylinder frames. In 2014, around 48 000 ships transported more than half of the world’s commercial goods across the oceans propelled by MDT two- and four-stroke diesel engines, with a power output of up to 87 MW. Combined capabilities: System suppliers deliver moreĭruckguss Westfalen Behringer in Velbert and Druckguss Westfalen in Geseke operate together as a successful system supplier: With our large capability portfolio – from high-quality zinc die cast and aluminium die cast components and machining to surface finishing and plating for fully ready-to-fit parts – we can serve a huge variety of individual product needs.Ĭlick here to see components additionally available on order from Druckguss Westfalen.MAN Diesel Technology (MDT) engines have been renowned for their quality for decades. It also conserves resources: Sustainability is a central issue for Druckguss Westfalen Behringer.
The benefits of this methodical approach speak for themselves: We work highly efficiently right from the outset, thinking ahead with our full focus on customer needs. As we implement your project, we optimise for all key parameters: application, alloy, quality and tolerance relative to other parts, service life, and any weak points with regard to the planned use.
Magmasoft: Top-level production optimisationīefore production starts, we simulate components using Magmasoft simulation software and then go on to design tools and optimise them in collaboration with the customer. We combine our capabilities to your advantage in order to eliminate weaknesses as early as possible – in fact, as early as the bid preparation stage. Expert and results-focused: Advice when you need it Casting simulation: From the idea to the market-ready productĭruckguss Westfalen Behringer in Velbert and Druckguss Westfalen in Geseke have the latest in-house technology to assist customers in die cast component design. In this way, we work in close consultation with you to develop the ideal, cost-efficient component. Both sides benefit equally from the result: Based on clear knowledge of your ideas, wishes and expectations, we can select exactly the right die casting solution for your product. Our collaborative approach is based on mutual esteem, trust and respect. Die casting consulting: Partnership for the perfect productĪccording to your needs, we are there to support you right from the initial design stage, working to achieve the optimum commercial and engineering outcome for your product. That is why we attach such great importance to die casting consultant services and casting simulation. At Druckguss Westfalen Behringer we know that listening to and working shoulder to shoulder with customers is the only way to achieve top-quality die cast parts.