Optimization of the aluminium die casting process based on the Taguchi method

Abstract

Porosity in the die casting process causes costly scrap loss and limits the use of die-cast parts in critical high-strength applications. The amount of porosity is closely related to the die casting process parameters. Consequently, the mechanisms of porosity formation in relation to die casting parameters have to be studied in detail. A considerable reduction in porosity formation can be obtained by Taguchi technique implementation in the die casting process. Through simple multifactorial experiments in the foundry, controllable factors can be isolated to provide centring and variance control for a process variable. The primary objective of this paper is to investigate the effects of process parameters on porosity formation in the pressure die casting process to improve casting quality. Examples of the off-line technique used in a Greek aluminium die casting company are given for the purpose of illustrating the practicality and ease of use by industry engineers and managers.