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A secondary constraint is the possible range of preferred dimensions promised in the sales prospectus. In order to explore the design space of the filling process, MagmaSoft® was used to perform a solver run. The general setup of the model can be found in Table 3. The solver was used to simulate the transition from the molten, liquid-like material through the solidified state and into the empty cavity. The many variations in the process of filling, cooling and solidification that were investigated using the solver had already been determined in the optimization process. The simulations of the filling time were in the range of 3 min to 10 min, well beyond the value of 12 seconds.
Figure 4 shows the optimized model. The cumulative number of output parameters ranged from 755 to 841. The number of degrees of freedom (NDoFs) in each optimization run was between 228 and 247. The 10 best frames are shown in Figure 4. The parameters that affected the minimum filling time were, in order of importance, the length of the runner that was connected to the gating slot, the cross-section of the gating slot, and the height of the vertical slot in the gating slot.
Figure 5 shows the complete filling sequence that was achieved with the best design. The value for the maximum filling time was scaled to 12 seconds. In this design, the maximum filling time for the process was 2.2064 seconds. The mean value was achieved in 2.3068 seconds with a standard deviation of 0.0117 seconds.
Based on the results of the simulation, MagmaSoft® was used to design a new gating system with both optimized dimensions. The completely new gating system consisted of two bars with tapered sleeve geometries in the horizontal slot and a vertical slot in the gating slot (see Figure 5). The horizontal sleeves served the function of the original straight cuts with tapered ends. The new vertical slots cut to the bottom of the tapered rigid bar could improve the jetting of the primary magma through the narrow gating slot. d2c66b5586