Optimization of Process Parameters of Pressure Die Casting using Taguchi Methodology
Authors: Satish Kumar, Arun Kumar Gupta, Pankaj Chandna
Abstract:
The present work analyses different parameters of pressure die casting to minimize the casting defects. Pressure diecasting is usually applied for casting of aluminium alloys. Good surface finish with required tolerances and dimensional accuracy can be achieved by optimization of controllable process parameters such as solidification time, molten temperature, filling time, injection pressure and plunger velocity. Moreover, by selection of optimum process parameters the pressure die casting defects such as porosity, insufficient spread of molten material, flash etc. are also minimized. Therefore, a pressure die casting component, carburetor housing of aluminium alloy (Al2Si2O5) has been considered. The effects of selected process parameters on casting defects and subsequent setting of parameters with the levels have been accomplished by Taguchi-s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L18 orthogonal array. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the percent contribution of different process parameters. Confidence interval has also been estimated for 95% consistency level and three conformational experiments have been performed to validate the optimum level of different parameters. Overall 2.352% reduction in defects has been observed with the help of suggested optimum process parameters.
Keywords: Aluminium Casting, Pressure Die Casting, Taguchi Methodology, Design of Experiments
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1071190
Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 7339References:
[1] Anastasiou, K. S., "Optimization of the aluminium die casting process based on the Taguchi method." Journal of engineering manufacture. Vol. 216, No.7, pp 969 - 977, 2002.
[2] Barua, P. B., Kumar P., Gaindhar J. L., "Surface roughness optimization of V-process casting through casting method, AFS transition. Vol. 45, pp. 733-768, 1997.
[3] Byne, D. M., Taguchi, T., "The taguchi approach to parameter design, quality progress, pp. 19-26, 1987.
[4] Cowie, J. G., Peters, D. T., Brush, E. F. and Midson, S. P., "Materials & Modifications to Die Cast the Copper Conductors of the Induction Motor Rotor" Die Casting Engineer. Pp. 38-46, 2001.
[5] Guharaja, S., Noorul, H. A, Karuppannan, K. M, "Optimization of green sand casting process parameters by using Taguchi-s method." International Journal of Advance Manufacturing Technology. Vol. 30, No. 11, pp. 1040 - 1048, 2006.
[6] Janudom, S., Rattanochaikul, T., Burapa, R., Wisutmethangoon S., and Wannasin J., "Feasibility of semi-solid die casting of ADC12 aluminum alloy." Transaction of Nonferrous Metal Society of China. Vol. 20, No. 9, pp. 1756- 1762, 2010.
[7] Noorul, H. A., Guharaja, S. and. Karuppannan K. M. "Parameter optimization of CO2 casting process by using Taguchi method." International Journal Interactive Design and Manufacturing. Vol. 3, No.1, pp. 41-50, 2009.
[8] Oktem, H., Erzurumlu, T. and Col, M. A. study of the Taguchi optimization method for surface roughness in finish milling of mold surfaces. International. Journal Advance Manufacturing Technology. Vol. 28, pp. 694-700, 2006.
[9] Ross, P.J. "Taguchi Techniques for Quality Engineering." McGraw- Hill Book, New York 1988.
[10] Syrcos, G. P. "Die casting process optimization using Taguchi method." Journal of Material Processing Technology, Vol. 135, pp. 68-74, 2003.
[11] Taguchi, G. "Introduction to Quality Engineering." Asian Productivity Organization, Tokyo, Japan 1986.
[12] Tsoukalas, V. D., Mavrommatis, S. A., Orfanoudakis, N. G. and Baldoukas A. K.- "A study of porosity formation in pressure die casting using the Taguchi approach." Journal of Material science and engineering" Vol. 218, No. 1, pp. 77-86, 2004.
[13] Yang, J. L. and Chen, J. C., "A Systematic Approach for Identifying Optimum Surface Roughness Performance in End-Milling Operations." Journal of Industrial Technology. Vol. 17, No.2, pp. 2-8, 2001.