Quantitative Experimental Study of Defects Induced by Process Parameters in the High-Pressure Die Cast Process

Sharifi, Pouya; Jamali, Jamaloddin; Sadayappan, Kumar; Wood, Jeffrey

doi:10.1007/s11661-018-4633-0

Cited by 14 publications

(1 citation statement)

References 21 publications

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“…[16] P. SHARIFI et al quantitatively studied the influences of slow and fast stage velocities, intensification pressure and die temperature on the amount of various defects such as shrinkage and gas prosity in high-pressure die cast magnesium alloy components by using the commericial casting simulation package, ProCAST TM . [17] O¨zlem Boydak et al investigated mold filling, solidification, temperature distribution, porosity and velocity of the molten metal during HPDCP for aluminium alloy AlSi12Cu flange part through the computer simulation and obtained optimum parameters from simulation results. [18] Elena Fiorese et al conducted computational analysis and experimental assessment of effect of the plunger speed on tensile properties in high-pressure die casting using the software MAGMASOFT.…”

Section: Introductionmentioning

confidence: 99%

High-pressure die casting process optimization for improving shrinkage porosity and air entrainment in carburetor housing with aluminum alloy using Taguchi-based ProCAST simulation and MADM-based overall quality index

Kim,

Hong,

Yang

et al. 2024

Int J Adv Manuf Technol

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Many practical high pressure die casting process (HPDCP) optimization problems are multi-objective optimization ones that optimize multiple quality attributes of castings. This paper proposes a new HPDCP optimization method for improving shrinkage porosity and air entrainment using Taguchi-based ProCAST simulation and multi-attribute decision making (MADM)-based overall quality index. Taguchi orthogonal array is used to design ProCAST simulation experiment. MADM is used to convert multiple quality attributes into a single overall quality index (OQI). Taguchi optimization method is used to determine optimal HPDCP parameters to maximize the OQI. By using the proposed method, this paper determines the optimal HPDCP parameters such as pouring temperature (PT), filling rate (FR), piston velocity (PV) and preheating mold temperature (PMT) for improving volume of shrinkage porosity (VSP) and air entrainment (AE) in carburetor housing with aluminum alloy AlSi9Cu1Mg. The optimal HPDCP parameters are PT of 640 o C, FR of 40 %, PV of 6.5 m/s, and PMT of 150 o C. The PT is the most effective HPDCP parameter for improving the VSP and AE, and the next are FR, PV and PMT. The proposed method could be actively applied to not only HPDCP but also other casting processes and other manufacturing processes.

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Section: Introductionmentioning

confidence: 99%