Geometrical Parametric Optimisation of A356 Alloy Composite in a Two-Stage Casting Process for Automobile Wheel Covers using Response Surface Methodology

Abstract

In recent years, novel products from out–of–use A356 alloy engine components are increasingly produced for the automobile industries. Despite being a promising method the sand casting of these products reveals an inadequately understood cast geometry phenomenon for the process. At present, there is no technical solution to the optimisation of cast geometries for A356 alloy reconfigured into composites through organic matter reinforcements. This paper models and analyse sand casting process product geometries in a two–phase method. It utilises the response surface methodology with data on inputs and outputs to create the regression. Volume and density of the first casting process and the weight loss were evaluated for the various groupings of casting process variables, including length, weight, height, width of product for the first casting, weight, length, breadth of the product for the second casting, and the total weight of organic materials. The input and output associations were established in two models of regression analysis representing the central composite design, CCD. The influences of the cast geometrical variables on the evaluated responses were analysed. Furthermore, the predictive accuracy of the two regression models was evaluated. Results revealed that the applied CCD and the regression models reveals statistical adequacy and are competent to predict accurately.