Minimum Porosity Formation in Pressure Die Casting by Taguchi Method

Die casting process is significantly used in the industry for its high productivity and less postmachining requirement. Due to light weight and good formability, aluminum die casting plays an important role in the production of transportation and vehicle components. In the current study of die casting for Automobile starter motor casing, the following issues are focused: shot piston simulation, defect analysis, and, finally, the use of the Taguchi multiquality analytical method to find the optimal parameters and factors to increase the aluminium ADC10 die casting quality and efficiency. Experiments were conducted by varying molten alloy temperature, die temperature, plunger velocities in the first and second stage, and multiplied pressure in the third stage using L27 orthogonal array of Taguchi method. After conducting a series of initial experiments in a controlled environment, significant factors for pressure die casting processes are selected to construct an appropriate multivariable linear regression analysis model for developing a robust performance for pressure die casting processes. The appropriate multivariable linear model is a useful and efficient method to find the optimal process conditions in pressure die casting associated with the minimum shrinkage porosity percent.