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Optimization of High Pressure Die Casting Process using Taguchi method and Computer Aided Casting Simulation Technique

This paper presents approach to design an optimal mould using advantage of the simulation tools. The considered casting process is high pressure die casting process which is used to manufacture complex shaped products in light alloys. Combination of the design of experiments and computer assisted casting simulation techniques allow the die filling process to be evaluated and help faster optimization of the cavity mould geometry and process parameters. Simulation of casting process was performed, according to the Taguchi based L9 orthogonal array. Output prcess variables were filling time and schrinkage obtained in the end of simulation process. Gray relational analysis and analysis of variance were performed. Analysis of variance results indicate that the cavity mould geometry has the most significant influence on the filling time and shrinkage of the casting. Number of iterations using casting simulation software NOVAFlow&Solid was performed for mould filling and solidification analysis.

High-pressure die casting Taguchi method Castings parameters NOVAFlow&Solid

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