The work presented aims to simulate the computer simulation of manganese steel wear parts of Sandvik’s Rock Crusher and match the actual foundry conditions.

Thermophysical properties like thermal conductivity, specific heat and density of different grades of Hadfield steel like M1, M2 and M7 along with Olivine sand is calculated by experimental methods such as Differential scanning calorimeter, Laser flash and Dilatometer in Jönköping University. Using the data obtained from the experiments, new datasets are created in MAGMA to run the simulation.

A real time casting experiment with thermocouples to measure the cooling curves was carried out in order to match the foundry conditions through MAGMA simulation to get a good fit and to ease the predictability of the quality of the wear parts.

Optimization tool in MAGMA is used to create the design of experiments in order to match the curves by keeping HTC in consideration. Results from the design simulation give an idea as to how much HTC varies from the lower limit to higher limit. Going forward, a new HTC dataset is created to optimize the simulation to higher accuracy