Minimizing the Casting Defects in High Pressure Die Casting Using Taguchi Analysis
Scientia Iranica. International Journal of Science and Technology
High-Pressure Die Casting (HPDC) is one of the major production processes of automotive industry, widely used to manufacture geometrically complex nonferrous castings. The mechanical strength and microstructure of HPDC-manufactured products changes with variation in several process parameters such as injection pressure, molten temperature, 1 st and 2 nd stage plunger velocity, cooling temperature etc. Since these process parameters directly affect casting quality, therefore, their optimum
... ation is needed to maximize productivity of the process and minimize casting defects such as porosity, pinholes, blowholes, etc. Hence, to tackle this problem, an approach is presented in this paper that minimizes the major casting defect, i.e., porosity, in the HPDC process by optimizing parameters through Design of Experiments (DOE) in combination with a Taguchi Analysis. The results obtained showed that cooling time, injection pressure, and 2 nd stage plunger velocity have a major influence on the response factor (density of the cast part). It was further concluded that, by using: a 178 bar injection pressure, 665 °C molten temperature, 5 seconds of cooling time, 210 °C mold temperature, 0.20 m·s −1 1 st stage plunger velocity, and 6.0 m·s −1 2 nd stage plunger velocity, the rejection rate of the selected part due to porosity was reduced by 61%.