On process modelling of cold chamber die casting of Al alloy by using buckingham’s Π approach

Abstract

In the present study, outcome of Taguchi based model has been used for mathematical modelling of Al alloy cast component weight (W) by using Buckingham’s π approach in cold chamber (CC) die casting process. During mass production of CC die casting components, W measurement is used as one of the yardstick to ensure defect free casting. Three input parameters namely 1st phase pressure (Pr1); 2nd phase pressure (Pr2); and limit switch (LS) position were selected to give output in form of cast component W based upon Taguchi design. The macro model based upon Taguchi design has been further used for micro modelling of W in CC die casting using Buckingham’s Π approach in form of mathematical equation. It was observed that ratio of die opening time for maximum W (Wmax) to minimum W (Wmin) was 1.06. This study provides main effects of Pr1, Pr2 and LS variables on casting ‘W’ and shed light on controlling the casting defects in CC die casting process for shop floor decisions. The comparison with experimental results has been made for further validation of model.