Optimizing process parameters to reduce blowholes in high pressure die casting using Taguchi methodology

N. Rathinam ⇑
, R. Dhinakaran, E. Sharath
Department of Mechanical Engineering, Pondicherry Engineering College, Pillaichavady, Puducherry, 605014, India

Abstract

Products manufactured from every manufacturing process exhibit some defects. To supply quality products to the customer these defects must be reduced. The motivation for this work is to reduce defects in end products reaching customers, thereby increasing productivity. The objective of present work is to reduce the rejection of parts due to blowhole defects that arise during High Pressure Die Casting (HPDC) process.

The casting product selected for this study is rack housing made of aluminium alloy (ADC 12) connected with steering column of automobiles. The process parameters taken for study are Limit Switch Position, Intensification Pressure, Phase-1 Velocity and Phase-2 Velocity. Density of casting is chosen as the response factor for the parameters taken for study.

Taguchi parameter design approach is used to optimize the process parameters. By varying the selected process parameters with various levels obtained through Taguchi method different experiments were conducted. The experiments are conducted based on L25 orthogonal array.

To determine the percent contribution of various process parameters ANOVA have been performed. The optimum process parameters were obtained for minimum blowhole in HPDC of ADC 12 alloy. The optimum process parameters level obtained using Taguchi technique to minimize castings defects for Limit Switch Position, Intensification Pressure, Phase-1 Velocity and Phase-2 Velocity are 170 mm, 300 kg/cm2 , 1 m/s and 4 m/s respectively.  2020 The Authors. Published by Elsevier Ltd.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/bync-nd/4.0) Selection and Peer-review under responsibility of the scientific committee of the International Conference & Exposition on Mechanical, Material and Manufacturing Technology.

Korea

모든 제조 공정에서 제조된 제품은 일부 결함이 있습니다. 고객에게 양질의 제품을 공급하려면 이러한 결함을 줄여야 합니다. 이 작업의 동기는 고객에게 도달하는 최종 제품의 결함을 줄여 생산성을 높이는 것입니다. 현재 작업의 목적은 HPDC (High Pressure Die Casting) 공정에서 발생하는 블로우 홀 결함으로 인한 부품 불량을 줄이는 것입니다.

본 연구를 위해 선정 된 주물 제품은 자동차의 스티어링 칼럼과 연결된 알루미늄 합금 (ADC 12) 재질의 랙 하우징이다. 연구를 위해 취한 프로세스 매개 변수는 Limit Switch Position, Intensification Pressure, Phase-1 Velocity 및 Phase-2 Velocity입니다.

주조 밀도는 연구를 위해 취한 매개 변수에 대한 응답 계수로 선택됩니다. Taguchi 매개 변수 설계 접근 방식은 공정 매개 변수를 최적화하는 데 사용됩니다. Taguchi 방법을 통해 얻은 다양한 수준으로 선택한 공정 매개 변수를 변경하여 다양한 실험을 수행했습니다.

실험은 L25 직교 배열을 기반으로 수행됩니다. 다양한 공정 매개 변수의 백분율 기여도를 결정하기 위해 ANOVA가 수행되었습니다. ADC 12 합금의 HPDC에서 최소 블로우 홀에 대해 최적의 공정 매개 변수를 얻었습니다.

Limit Switch Position, Intensification Pressure, Phase-1 Velocity 및 Phase-2 Velocity에 대한 주조 결함을 최소화하기 위해 Taguchi 기술을 사용하여 얻은 최적의 공정 매개 변수 수준은 각각 170mm, 300kg / cm2, 1m / s 및 4m / s입니다. 2020 저자. Elsevier Ltd에서 발행합니다.
이 문서는 CC BY-NC-ND 라이선스 (https://creativecommons.org/licenses/bync-nd/4.0)에 따른 오픈 액세스 문서입니다. 기계, 재료 및 제조 기술에 관한 국제 회의 및 박람회.

Fig. 1. Cause and effect diagram.
Fig. 2. 3D view of Rack Housing.
Fig. 2. 3D view of Rack Housing.

Fig. 3. Casting samples.
Fig. 3. Casting samples.
Fig. 4. Response plot for Mean (casting density).
Fig. 4. Response plot for Mean (casting density).
Fig. 5. Response plot for S/N ratio
Fig. 5. Response plot for S/N ratio
Fig. 6. Percentage contributions of control factors

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