Modelling and multi-objective optimisation of squeeze casting process using regression analysis and genetic algorithm

Abstract

In the present work, an attempt has been made using statistical tools to develop a non-linear regression model and to identify the significant contribution of squeeze cast process parameters on surface roughness, hardness and tensile strength. Microstructure examination performed on the squeeze cast samples has revealed that a maximum of 100 MPa pressure is good enough to eliminate all possible casting defects. Accuracy of the developed models has been tested with the help of ten test cases. It is important to note that the developed models predict responses with a reasonably good accuracy and the developed mathematical input–output relationship helps the foundry-man to make better predictions. The present work comprises four objectives, which are conflicting in nature. Hence, mathematical formulation is used to convert four objective functions into a single objective function. The popular evolutionary algorithm, that is genetic algorithm has been utilised to determine the optimal process parameters.