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In other words, it is used to find cause-and-effect relationships.

Even though there were more designs to be calculated for a virtual DoE, there was one significant advantage to proceed with this method: to determine the relationship between the variables (input) and the casting defect (objective). Total 8 different designs were created based on the combination of the 3 above variables. Instead of calculating the 3 new versions, a virtual Design of Experiment was prepared using MAGMASOFT® autonomous engineering technology. Both the runner modifications and additional machining allowance were the changes intended to eliminate the reoxidation issue. The chill was added to reduce the centreline shrinkage or also known as microporosity which was also present even though it was not the reason for the quality issue. See Pic 2: Different Version which was given by the foundry.

Possible design modifications and constraints were discussed and finally there were 3 different modifications allowed to be implemented: the usage of chill, different runner design as well as additional machining allowance. The optimization project had a clear objective now: to reduce the reoxidation inclusion. After a few round of discussion with MAGMA engineers, the foundry engaged us in the hope of reducing the quality issue as welding was not a feasible option in the long run. Several attempts on resolving this issue by the means of conventional trial and error did not succeed. The bearing housing was already in production for quite some time the casting defect did not really lead to a casting reject however they needed to spend a lot of resources (money and time) for repairing it through welding process. MAGMA Singapore, being the headquarter for MAGMA in Asia Pacific region, is not only providing licenses and trainings but has a vast track record of quickly solving various casting defect issues through engineering services. Being a MAGMASOFT® license user in Japan, they decided to consult MAGMA Singapore for assistance in identifying and solving this steel casting issue. A steel foundry in Indonesia which is a subsidiary of a Japanese machine maker for construction and mining industry was facing quality issue with one of their parts: the Bearing Housing.