Optimization of Gating System Design for Die Casting Process with Minimizing the Casting Defects

Mechanical Engineering

Thousands of consumers, commercial, and industrial products can be produced by die casting process with high volume ranging from small to large components and hence die casting can be referred as mass production process. Some of the products produced by die casting was defective and hence needs to improve the performance of the process. The objective of the present work is to evaluate the effect of injection pressure of the molten metal, filling time, gate length and gate width on the dimensional stability of the die cast part. In order to investigate the effect, process parameters such as injection pressure of the molten metal, filling time, gate length and gate width Response Surface Methodology (RSM) with Face Center Design (FCD) has been used. The experiments were carried out according to design matrix of L27 orthogonal array. Two response or defect namely shrinkage porosity (%) and hot tears (%) were considered in this work. The RSM model was developed for each response. Analysis of variance (ANOVA) for each response has been also carried out to find out the influence factors and their interactions. Finally, optimization and confirmation test has been carried out and the optimized input parameters were validated by conducting experiments and predict the optimum response. The modeled and experimental results have been compared and an error of 26% and 24 % has been observed for both responses with 98% of desirability.

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