This document summarizes a study that used Taguchi methodology to examine the effect of die casting process parameters on porosity levels in aluminum alloy SAE 308. An experiment was conducted using an L9 orthogonal array to test combinations of four process parameters (first phase speed, second phase speed, first phase length, and injection pressure) at three levels. Porosity measurements were taken for each sample and analyzed. ANOVA results showed injection pressure had the greatest effect on porosity levels at 43.64%, followed by first phase length at 28.39%. Predicted porosity levels and a 95% confidence interval were also estimated based on the optimal parameter settings.
Dynamic Modulus Master Curve Construction Using Christensen-Anderson-Marastea...IJERA Editor
Dynamic modulus is a fundamental property used in most mechanistic analysis of pavement response as well as material input for design of flexible pavement. Correspondingly, the E* of HMA master curve incorporated time and temperature effects. The aim of this study is to obtain dynamic modulus and phase angle data using the Christensen-Anderson-Marasteanu (CAM) model based on master curve. Samples were prepared according to the AASHTO TP 62-03 Standard Test Method for Determining Dynamic Modulus of Hot-Mix Asphalt Concrete Mixtures. The results show that the dynamic modulus is decreasing with increase of temperature for all mixtures while it is opposite trend with the phase angle. In terms of resistance of rutting, the JAPAN AC-20 is a good potential mix at frequency of 25 and 10 Hz while USA and JAPAN AC-13 mixes are good for fatigue resistance at same frequency respectively. From the Goodness-of-fit statistics, all the mixture gave an excellent correlation when R^2≥0.90 and Se/Sy ≤0.35. Nonetheless, the correlation coefficient R^2 is not always a reliable coefficient to measure the Goodness-of-fit for nonlinear regression analysis. Furthermore, they may have local or overall biases in the predictions that can reduce significantly its accuracy under certain conditions.
INFLUENCE OF PROCESS PARAMETERS ON SURFACE ROUGHNESS AND MATERIAL REMOVAL RAT...ijmech
Optimization of machining parameters is very valuable to maintain the accuracy of the components and
obtain cost effective Machining.MRR (material removal rate) and surface roughness is playing primary
role in manufacturing using contemporary CNC (computer numerical controlled) machines, in the case of
mass manufacturing. In present study experimental and work is done for optimization of process
parameters. In experimental work total 32 experiments are designed according DOE method “Mixed
taguchi”. Three factors are selected for experimental work. Depth of cut, speed and feed rate is selected
factors for experimental work. All experiments are carried out in CIPET, Jaipur. Two responses are find
out in this work and are following: first one is material removal rate (MRR) and second response is surface
roughness (Ra) measurement. An artificial neural network is ‘Feed Forward Back Propagation’ type
model of developing the analysis and prediction of surface roughness and MRR with relationship between
all input process parameters
The Effect of Process Parameters on Surface Roughness in Face Millinginventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
Dynamic Modulus Master Curve Construction Using Christensen-Anderson-Marastea...IJERA Editor
Dynamic modulus is a fundamental property used in most mechanistic analysis of pavement response as well as material input for design of flexible pavement. Correspondingly, the E* of HMA master curve incorporated time and temperature effects. The aim of this study is to obtain dynamic modulus and phase angle data using the Christensen-Anderson-Marasteanu (CAM) model based on master curve. Samples were prepared according to the AASHTO TP 62-03 Standard Test Method for Determining Dynamic Modulus of Hot-Mix Asphalt Concrete Mixtures. The results show that the dynamic modulus is decreasing with increase of temperature for all mixtures while it is opposite trend with the phase angle. In terms of resistance of rutting, the JAPAN AC-20 is a good potential mix at frequency of 25 and 10 Hz while USA and JAPAN AC-13 mixes are good for fatigue resistance at same frequency respectively. From the Goodness-of-fit statistics, all the mixture gave an excellent correlation when R^2≥0.90 and Se/Sy ≤0.35. Nonetheless, the correlation coefficient R^2 is not always a reliable coefficient to measure the Goodness-of-fit for nonlinear regression analysis. Furthermore, they may have local or overall biases in the predictions that can reduce significantly its accuracy under certain conditions.
INFLUENCE OF PROCESS PARAMETERS ON SURFACE ROUGHNESS AND MATERIAL REMOVAL RAT...ijmech
Optimization of machining parameters is very valuable to maintain the accuracy of the components and
obtain cost effective Machining.MRR (material removal rate) and surface roughness is playing primary
role in manufacturing using contemporary CNC (computer numerical controlled) machines, in the case of
mass manufacturing. In present study experimental and work is done for optimization of process
parameters. In experimental work total 32 experiments are designed according DOE method “Mixed
taguchi”. Three factors are selected for experimental work. Depth of cut, speed and feed rate is selected
factors for experimental work. All experiments are carried out in CIPET, Jaipur. Two responses are find
out in this work and are following: first one is material removal rate (MRR) and second response is surface
roughness (Ra) measurement. An artificial neural network is ‘Feed Forward Back Propagation’ type
model of developing the analysis and prediction of surface roughness and MRR with relationship between
all input process parameters
The Effect of Process Parameters on Surface Roughness in Face Millinginventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
Weld Improvement Example in Offshore Oil & GasImran Choudury
Weld improvement examples in offshore oil and gas platforms. Professional training courses in the energy industry, Methods to manage corrosion and crack growth. Where to perform grinding by a burr grinder?
Today operators are faced with the challenges
of ageing offshore installations and the consumed fatigue lives of their structural details. As contracts of offshore installations are renewed or extended, engineers are faced with the challenge to extend the fatigue life of assets for a new required period of time. This training will help engineers and naval architects to tackle these challenges,
Implementation of Response Surface Methodology for Analysis of Plain Turning ...IJERD Editor
This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface roughness of mild steel material with turning process. The response surface methodology (RSM) was employed in the experiment. The investigated turning parameters were cutting speed (CS) (1150, 850m/min), feed rate (FR) (1 and 0.5 mm/rev) and depth of cut (DOC) (1.0 and 0.5 mm) and no. of cuts(NOC) (2 and 1). The results showed that the interaction between the feed rate and depth of cut, was the primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The optimum condition required for minimum surface roughness(SR) include cutting speed of 1150 m/min, feed rate of 1 mm/rev, axial depth of cut of 0.5 mm and no. of cut 1. With this optimum condition, a surface roughness of 0.280μm was obtained. The methodology for above experimentation is presented in this paper along with results and interpretation.
An Experimental Study of the Effect of Control Parameters on the Surface Roug...IOSR Journals
Surface quality is one of the specified manufacturer requirements for machined parts. There are
many parameters that have an effect on surface roughness, but those are difficult to quantify adequately in
finish turning operation such as cutting speed, feed rate, and depth of cut are known to have a large impact on
surface quality. The Taguchi method is one of the statistical tools, to investigate influence of surface roughness
by cutting parameters such as cutting speed, feed and depth of cut. The Taguchi process helps to select or to
determine the optimum cutting conditions for turning process. Many researchers developed many mathematical
models to optimize the cutting parameters to get lowest surface roughness by turning process. The Taguchi
design of experiments was used for optimizing quality and performance output of manufacturing processes.
Analysis and Optimization Of Boring Process Parameters By Using Taguchi Metho...inventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Analysis of Process Parameters for Optimization of Plastic Extrusion in Pipe ...IJERA Editor
The objective of this paper is to study the defects in the plastic pipe, to optimize the plastic pipe manufacturing process. It is very essential to learn the process parameter and the defect in the plastic pipe manufacturing process to optimize it. For the optimization Taguchi techniques is used in this paper. For the research work Shivraj HY-Tech Drip Irrigation pipe manufacturing, Company was selected. This paper is specifically design for the optimization in the current process. The experiment was analyzed using commercial Minitab16 software, interpretation has made, and optimized factor settings were chosen. After prediction of result the quality loss is calculated and it is compare with before implementation of DOE. The research works has improves the Production, quality and optimizes the process.
Analysis and Optimisation of High Pressure Die Casting Parameters to Achieve ...Dr. Amarjeet Singh
A numerical simulation approach is proposed to predict the optimal parameter setting during high pressure die casting. The contribution from the optimal parameters, the temperature, showed more influence on the casting quality than the other parameters. This study’s outcome was beneficial for finding the solution for casting defects that occurs due to incorrect setting of process parameters in die casting. Thus, a combination of numerical optimisation techniques and casting simulation serves as a tool to improve the casting product quality in die casting industries. This paper aims to analyse and optimise critical parameters like injection pressure, molten metal temperature, holding time, and plunger velocity, contributing to the defects. In this research paper, an effort has been made to give optimal pressure, temperature, holding time, and plunger velocity parameters using ProCAST simulation software that uses finite element analysis technology. Numerical analysis for optimising the parameters by varying the temperature of molten metal, injection pressure, holding time, and plunger velocity, concerning solidification time at hot spots, is an essential parameter for studying the defect analysis in the simulated model.
Optimization of Material Removal Rate & Surface Roughness in Dry Turning of M...IJERA Editor
Optimization of machining parameters is valuable to maintain the accuracy of the components and to minimize
the cost of machining. Surface finish is an important measure for the quality of the machined parts. The present
work is an experimental investigation to study the effect of machining parameters on Material Removal Rate
and Surface Roughness in dry turning of medium carbon steel EN19. Taguchi’s single objective optimization
method was used to find the effect of input parameters on the responses. The experiments were conducted as per
Taguchi’s L9 Orthogonal Array on CNC lathe under dry conditions. Cutting parameters of speed, feed and
depth of cut were taken as inputs and machining was done by PVD TiAlN tool. Regression models for the
responses were prepared by using MINITAB-16 software. Analysis of variance (ANOVA) was used to find the
influence of machining parameters on the responses. From the ANOVA results, it is clear that speed has high
influence followed by feed and depth of cut has very low influence in achieving the optimum values for both
Material Removal Rate and Surface Roughness. Finally, experimental and Regression values of responses were
compared. From the results, it is found that both the values are close to each other hence, the regression models
prepared were more accurate and adequate. Percentage of errors between experimental and regression values
were calculated and they found in the range of ±0.20.
Weld Improvement Example in Offshore Oil & GasImran Choudury
Weld improvement examples in offshore oil and gas platforms. Professional training courses in the energy industry, Methods to manage corrosion and crack growth. Where to perform grinding by a burr grinder?
Today operators are faced with the challenges
of ageing offshore installations and the consumed fatigue lives of their structural details. As contracts of offshore installations are renewed or extended, engineers are faced with the challenge to extend the fatigue life of assets for a new required period of time. This training will help engineers and naval architects to tackle these challenges,
Implementation of Response Surface Methodology for Analysis of Plain Turning ...IJERD Editor
This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface roughness of mild steel material with turning process. The response surface methodology (RSM) was employed in the experiment. The investigated turning parameters were cutting speed (CS) (1150, 850m/min), feed rate (FR) (1 and 0.5 mm/rev) and depth of cut (DOC) (1.0 and 0.5 mm) and no. of cuts(NOC) (2 and 1). The results showed that the interaction between the feed rate and depth of cut, was the primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The optimum condition required for minimum surface roughness(SR) include cutting speed of 1150 m/min, feed rate of 1 mm/rev, axial depth of cut of 0.5 mm and no. of cut 1. With this optimum condition, a surface roughness of 0.280μm was obtained. The methodology for above experimentation is presented in this paper along with results and interpretation.
An Experimental Study of the Effect of Control Parameters on the Surface Roug...IOSR Journals
Surface quality is one of the specified manufacturer requirements for machined parts. There are
many parameters that have an effect on surface roughness, but those are difficult to quantify adequately in
finish turning operation such as cutting speed, feed rate, and depth of cut are known to have a large impact on
surface quality. The Taguchi method is one of the statistical tools, to investigate influence of surface roughness
by cutting parameters such as cutting speed, feed and depth of cut. The Taguchi process helps to select or to
determine the optimum cutting conditions for turning process. Many researchers developed many mathematical
models to optimize the cutting parameters to get lowest surface roughness by turning process. The Taguchi
design of experiments was used for optimizing quality and performance output of manufacturing processes.
Analysis and Optimization Of Boring Process Parameters By Using Taguchi Metho...inventionjournals
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Analysis of Process Parameters for Optimization of Plastic Extrusion in Pipe ...IJERA Editor
The objective of this paper is to study the defects in the plastic pipe, to optimize the plastic pipe manufacturing process. It is very essential to learn the process parameter and the defect in the plastic pipe manufacturing process to optimize it. For the optimization Taguchi techniques is used in this paper. For the research work Shivraj HY-Tech Drip Irrigation pipe manufacturing, Company was selected. This paper is specifically design for the optimization in the current process. The experiment was analyzed using commercial Minitab16 software, interpretation has made, and optimized factor settings were chosen. After prediction of result the quality loss is calculated and it is compare with before implementation of DOE. The research works has improves the Production, quality and optimizes the process.
Analysis and Optimisation of High Pressure Die Casting Parameters to Achieve ...Dr. Amarjeet Singh
A numerical simulation approach is proposed to predict the optimal parameter setting during high pressure die casting. The contribution from the optimal parameters, the temperature, showed more influence on the casting quality than the other parameters. This study’s outcome was beneficial for finding the solution for casting defects that occurs due to incorrect setting of process parameters in die casting. Thus, a combination of numerical optimisation techniques and casting simulation serves as a tool to improve the casting product quality in die casting industries. This paper aims to analyse and optimise critical parameters like injection pressure, molten metal temperature, holding time, and plunger velocity, contributing to the defects. In this research paper, an effort has been made to give optimal pressure, temperature, holding time, and plunger velocity parameters using ProCAST simulation software that uses finite element analysis technology. Numerical analysis for optimising the parameters by varying the temperature of molten metal, injection pressure, holding time, and plunger velocity, concerning solidification time at hot spots, is an essential parameter for studying the defect analysis in the simulated model.
Optimization of Material Removal Rate & Surface Roughness in Dry Turning of M...IJERA Editor
Optimization of machining parameters is valuable to maintain the accuracy of the components and to minimize
the cost of machining. Surface finish is an important measure for the quality of the machined parts. The present
work is an experimental investigation to study the effect of machining parameters on Material Removal Rate
and Surface Roughness in dry turning of medium carbon steel EN19. Taguchi’s single objective optimization
method was used to find the effect of input parameters on the responses. The experiments were conducted as per
Taguchi’s L9 Orthogonal Array on CNC lathe under dry conditions. Cutting parameters of speed, feed and
depth of cut were taken as inputs and machining was done by PVD TiAlN tool. Regression models for the
responses were prepared by using MINITAB-16 software. Analysis of variance (ANOVA) was used to find the
influence of machining parameters on the responses. From the ANOVA results, it is clear that speed has high
influence followed by feed and depth of cut has very low influence in achieving the optimum values for both
Material Removal Rate and Surface Roughness. Finally, experimental and Regression values of responses were
compared. From the results, it is found that both the values are close to each other hence, the regression models
prepared were more accurate and adequate. Percentage of errors between experimental and regression values
were calculated and they found in the range of ±0.20.
Prediction of Fault in Distribution Transformer using Adaptive Neural-Fuzzy I...ijsrd.com
In this paper, we present a new method for simultaneous diagnosis of fault in distribution transformer. It uses an adaptive neuro-fuzzy inference system (ANFIS), based on Dissolved Gas Analysis (DGA). The ANFIS is first “trained†in accordance with IEC 599, so that it acquires some fault determination ability. The CO2/CO ratios are then considered additional input data, enabling simultaneous diagnosis of the type and location of the fault. Diagnosis techniques based on the Dissolved Gas Analysis (DGA) have been developed to detect incipient faults in distribution transformers. The quantity of the dissolved gas depends fundamentally on the types of faults occurring within distribution transformers. By considering these characteristics, Dissolved Gas Analysis (DGA) methods make it possible to detect the abnormality of the transformers. This can be done by comparing the Dissolved Gas Analysis (DGA) of the transformer under surveillance with the standard one. This idea provides the use of adaptive neural fuzzy technique in order to better predict oil conditions of a transformer. The proposed method can forecast the possible faults which can be occurred in the transformer. This idea can be used for maintenance purpose in the technology where distributed transformer plays a significant role such as when the energy is to be distributed in a large region.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Analysis and Optimisation of High Pressure Die Casting Parameters to Achieve ...Dr. Amarjeet Singh
A numerical simulation approach is proposed to predict the optimal parameter setting during high pressure die casting. The contribution from the optimal parameters, the temperature, showed more influence on the casting quality than the other parameters. This study’s outcome was beneficial for finding the solution for casting defects that occurs due to incorrect setting of process parameters in die casting. Thus, a combination of numerical optimisation techniques and casting simulation serves as a tool to improve the casting product quality in die casting industries. This paper aims to analyse and optimise critical parameters like injection pressure, molten metal temperature, holding time, and plunger velocity, contributing to the defects. In this research paper, an effort has been made to give optimal pressure, temperature, holding time, and plunger velocity parameters using ProCAST simulation software that uses finite element analysis technology. Numerical analysis for optimising the parameters by varying the temperature of molten metal, injection pressure, holding time, and plunger velocity, concerning solidification time at hot spots, is an essential parameter for studying the defect analysis in the simulated model.
EFFECT OF PROCESS PARAMETERS ON FLATNESS OF PLASTIC COMPONENT IAEME Publication
Dimensional changes because of shrinkage is one of the most important problem in production of plastic parts using plastic injection molding(PIM). In this study, effect of injection
molding parameters on surface flatness of plastic component is investigated and achieving the flatness according to customer requirement is the big task, for that this work is carried out.
Optimization of Turning Parameters Using Taguchi MethodIJMER
Abstract: Today in manufacturing and metal industries customer satisfaction is very important to
make own place in competitive market and also to make mirror image with faith in the heart of
customer, because customer gives preference to buy good quality product. In the metal and
manufacturing industries for the product low surface roughness is very important. Lowest surface
roughness assures not only good quality but also reduces manufacturing cost. In this paper the main
objective is to study effect of cutting speed, feed rate and depth of cut on surface roughness of mild steel
in turning operation and as a result of that the combination of optimum level of factors was obtained to
get lowest surface roughness. Experiments have been conducted using Taguchi’s experimental design
technique. An orthogonal array, signal to noise ratio, and analysis of variance are employed to
investigate cutting characteristics of mild steel using high speed steel. Experimental results show that
among the cutting parameter cutting speed is the most significant machining parameter for surface
roughness followed by feed rate and depth of cut.
Optimization of Process Parameters in Turning Operation of AISI-1016 Alloy St...IOSR Journals
This paper investigates the parameters affecting the roughness of surfaces produced in the turning
process for the material AISI-1016 Steel. Design of experiments was conducted for the analysis of the influence
of the turning parameters such as cutting speed, feed rate and depth of cut on the surface roughness. The
results of the machining experiments for AISI-1016 were used to characterize the main factors affecting
surface roughness by the Analysis of Variance (ANOVA) method. The feed rate was found to be the most
significant parameter influencing the surface roughness in the turning process.
Minimization of the Casting Defects Using Taguchi’s Methodinventionjournals
This paper is relates with casting defects like pinholes, scabs, sand holes, slag, mould shifting, parting line defects, runner & riser defects which mainly occurs in valve casting in foundry. The research on controlling the casting defects in foundry shop which comes in various check valves -PN 10 and these causes may results the reduction of quality of casting. Here we have studied minimize the casting defects using Taguchi’s method through change in various parameters like as pouring temperature, green strength, mould hardness and permeability. These experiments were conducted based on standard acceptable and foundry men experience in this casting organization for casting check valves -PN 10 of various sizes & types Significant changes are taken during controlling the parameters. First we collected the data as casting defects from AV VALVE Pvt Ltd, Agra. Identify The major defects which are scab, cold shut and shrinkage. Complete this task we analyze the cause of this casting defects with the help of fish bone diagram. So we conclude that there are four parameters responsible for these casting defects. 1. Pouring Temperature (oC) 2. Sand Particle Size (AFS) 3.Mould Hardness Number 4. Permeability Number First we define the range of these parameters and then we perform the casting process at different trial and find that average percentage rejection is 6.25 of the casting product. Then we apply the Taguchi’s method and use of MINITAB 17 software to find out the optimum solution. These optimum solutions were applied on casting process and the calculated the percentage rejection 4.416 of the products. Thus we could improve 1.25% in casting defects.
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 9, Issue 4 (Nov. - Dec. 2013), PP 12-17
www.iosrjournals.org
www.iosrjournals.org 12 | Page
Study of effect of process parameter setting on porosity levels of
aluminium pressure die casting process using Taguchi
Methodology
Kulkarni Sanjay Kumar1
, J K Sawale 2
, Sampath Rao3
1,3
Department of Mechanical Engineering, VREC College Nizamabad, JNTU HYD, India
2
Department of Mechanical Engineering, MGM’s College, SRTMU NND, India
Abstract : This paper discusses the study and examined effect of die casting process parameters on porosity in
aluminium alloy SAE 308 by using Taguchi method. In any die casting industry porosity is a very serious
problem faced by production department and also being an invisible defect it is not identified visually in running
production. It is shown in this work that die casting parameters which are related with machine such as first
phase speed, second phase speed, first phase length and injection pressure all have significant influence on
porosity level. The quality assessment of the die casting part was based on porosity measurement. The
experiment have been performed as per the combination of levels of different process parameters suggested by
L9 orthogonal array and conformation experiments have been performed to validate the optimum levels of
different parameters
Keywords: Aluminum casting, die casting, Taguchi Methodology, Design of Experiments, orthogonal array
I. Introduction
Pressure Die Casting Process (PDC) is a complex industrial system. In a typical die casting machine
the molten metal is poured in the shot sleeve through a ladle after the die is closed. A movement of plunger
(piston) forces the metal through the die resulting in that the moveable part coincides with the fixed part. Some
die casting machines allow for this plunger movement to be completed in four stages. However, typically it is
done in two stages only. The plunger starts initially with a low velocity, then the velocity increases during the
piston’s motion at a change over position, the length of travel of the piston in the low velocity up to the change
over point is known as first phase length and the injection pressure is decreases at the end when nearly all the
liquid metal is injected into the die and solidifies.. During this process taking place inside the shot sleeve the
flow of the metal inside the shot sleeve before plunger should be in laminar if these speeds, first phase length,
and injection pressure are not set properly the flow of metal will disturbed and convert into turbulence and there
will be possibility of formation of porosity during process [7]. Though die casting process has a large number of
parameters that may affect the quality of the casting some of these are controllable while others are noise
factors. Therefore, a die casting company can be an ideal place to apply Taguchi’s test method for continuous
and rapid quality improvement. In this experiment more importance is given for the parameter design stage. The
basic steps to investigate the role process parameters in porosity formation and to improve casting quality are
summarized below.
1. Determine the casting porosity as a quality characteristic
2. Select the most significant die casting parameters that cause variation in porosity.
3. Operate the die casting process under the experimental conditions dictated by the chosen L9 orthogonal array
(OA) and parameter levels. Collect data.
4. Analyses the data. An analysis of variance (ANOVA) table can be generated to determine the statistical
significance of the parameters. Response graphs are plotted to determine preferred levels of each parameter.
5. Make decisions regarding optimum setting of control parameters.
6. Predict the treatment casting porosity conditions that derive from the new optimum level of each parameter
II. Experimental procedure
In this experiment the die casting cell consists of 250 T die casting machine, a holding furnace, an
automatic lubrication for inner die surfaces, an automatic metal ladle, robot extractor and shot monitoring
system for analysis and investigation of different die casting parameters. The test component is a irregular shape
connecting rod part shown in Fig.1.
2. Study of effect of process parameter setting on porosity levels of aluminium pressure die casting
www.iosrjournals.org 13 | Page
Fig.1
Also percentage porosity was the primary quantitative measure in this investigation; the first step was
the accurate determination of sample density by immersion technique. All samples were weighed twice to check
the error and for repeatability of results on electronic weighing machine in grams. Volume of sample was
calculated by Archimedes principle that is volume of the water that solid displace when it is immersed in the
water is the same as the volume of the solid itself. The density was calculated by mass/volume for each sample.
Porosity was calculated by using relation [3] (1)
𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 % = 1 −
𝜌𝑠
𝜌𝑜
× 100
Where 𝜌𝑠 is the measured casting density and 𝜌𝑜 is the fully dense casting having no porosity
(3.25g/cm3
). Porosity is a type of quality characteristic with the objective ‘the lower the better’. Therefore the
S/N ratio was used for this of response and is given by [3] (2)
𝑆
𝑁 = − 10 log
1
𝑛
𝐷𝑖
2
𝑛
𝑖=1
The most significant parameters were selected are first phase speed as (factor A), second phase speed
as (factor B), first phase length as (factor C), Injection pressure as (factor D). The other parameters are kept
constant for entire experimentation. The selected process parameters, along with their ranges are given in Table1
The most significant parameters were selected are first phase speed as (factor A), second phase speed as (factor
B), first phase length as (factor C), Injection pressure as (factor D). The other parameters are kept constant for
entire experimentation. The selected process parameters, along with their ranges are given in Table1
Table1. Process parameters with their ranges and value at three levels
Parameter
designation
Process Parameters Range Level 1 Level 2 Level 3
A First Phase Speed (m/s) 0.25 – 0.87 0.25 0.56 0.87
B Second Phase Speed (m/s) 1.05 - 2.25 1.05 1.65 2.25
C First phase length (mm) 185- 250 185 217 250
D Injection Pressure (kg/cm2
) 220- 270 220 245 270
In this study an L9 orthogonal array with five columns and nine rows was used. This array has eight
degree of freedom and it can handle four process parameter. Each die casting parameter was assigned to a
column and nine die casting parameter combinations were tested. Therefore only nine experiments are required
to study the entire casting parameter space using the L9 orthogonal array. The experimental layout for the
casting parameters using L9 orthogonal array is shown in Table 3 [12, 13, 14]
3. Study of effect of process parameter setting on porosity levels of aluminium pressure die casting
www.iosrjournals.org 14 | Page
Table 4. Casting porosity values and S/N ratios against trial numbers
Porosity Rating Results
Ext No
Cntrol Factors
A B C D Sample 1 Sample 2 Sample 3 Average S.D
S/N Ratio
( η )dB
1 1 1 1 1 0.210 0.203 0.197 0.203 0.007 -13.833
2 1 2 2 2 0.171 0.168 0.170 0.170 0.002 -15.411
3 1 3 3 3 0.168 0.167 0.167 0.167 0.001 -15.534
4 2 1 2 3 0.176 0.170 0.171 0.172 0.003 -15.275
5 2 2 3 1 0.176 0.176 0.179 0.177 0.002 -15.047
6 2 3 1 2 0.170 0.179 0.170 0.173 0.005 -15.243
7 3 1 3 2 0.176 0.175 0.180 0.177 0.003 -15.044
8 3 2 1 3 0.178 0.184 0.177 0.180 0.004 -14.921
9 3 3 2 1 0.178 0.185 0.179 0.181 0.004 -14.867
M = 0.177 is overall mean porosity. The bold numbers for Experiment No 1 and 3 represents the max and min
porosity values. The overall mean value of η for the experiment region defined by factor levels in table 4 as [23]
(6)
𝑚 =
1
9
𝜂𝑖
9
𝑛=9 =
1
9
𝜂1 + 𝜂2 + ⋯ ⋯+ 𝜂9 = −15.019 𝑑𝐵
Using the S/N ratio data and porosity data available in Table 4 the average of each level of the four factors is
calculated and listed in Table 5 and 6. They are the separate effect of each factor and are commonly called main
effects. The Graph 1. Shows the relations between the factors of A, B, C, D and the porosity levels (average
effect response for porosity levels)
Table 5. Average effect response for S/N ratio ( η ) dB
LEVELS A B C D
1 -14.926 -14.717 -14.665 -14.582
2 -15.188 -15.126 -15.184 -15.232
3 -14.944 -15.214 -15.203 -15.243
MAX – MIN
RANK
0.262
4
0.497
3
0.538
2
0.661
1
MAX – MAXIMUM VALUE IN THE CORRESPONDING COLUMN
MIN – MINIMUM VALUE IN CORRESPONDING COLUMN
Table 6. Average effect response for casting porosity
LEVELS A B C D
1 0.18 0.184 0.185 0.187
2 0.174 0.175 0.174 0.173
3 0.179 0.173 0.173 0.173
MAX – MIN
RANK
0.006
4
0.011
3
0.012
2
0.014
1
MAX – MAXIMUM VALUE IN THE CORRESPONDING COLUMN
MIN – MINIMUM VALUE IN CORRESPONDING COLUMN
Table 3 L9 Experimental Combination
Expt no
First phase speed
(m/s) A
Second phase speed
(m/s)
B
First phase length (mm)
C
Injection pressure(kg/cm²)
D
1 0.25 1.05 185 220
2 0.25 1.65 217 245
3 0.25 2.25 250 270
4 0.56 1.05 217 270
5 0.56 1.65 250 220
6 0.56 2.25 185 245
7 0.87 1.05 250 245
8 0.87 1.65 185 270
9 0.87 2.25 217 220
4. Study of effect of process parameter setting on porosity levels of aluminium pressure die casting
www.iosrjournals.org 15 | Page
The next step is the analysis of variance (ANOVA). The relative magnitude of the factor effects are
listed in Table 7 and 8. A better feel for the relative effect of the different factors is obtained by the
decomposition of variance, which is commonly called as analysis of variance (ANOVA). This is obtained first
by computing the sum of squares. 〔12] (11) (12) (13) (14)
Total sum of squares = 𝜂𝑖
29
𝑖=1 = 𝜂1
2
+ 𝜂2
2
+ ⋯ ⋯+ 𝜂9
2
(11)
Sum of squares due to mean = (number of experiments) × m² (12)
Total Sum of squares and mean difference = 𝜂𝑖 − 𝑚 ²9
𝑖=1 (13)
Sum of the squares due to factor A
= [(number of experiments at level A1) × (mA1 – m) ² +
(number of experiments at level A2) × (mA2 m) ² +
(number of experiments at level A3)× (mA3 m) ²] (14)
Similarly the sum of squares due to factor B,C and D can be computed as respectively. Now all these sun of
squares are tabulated in Table 7 due to S/N ratio and in Table 8 due to porosity values. The contribution
percentage of all the four parameters has been estimated.
Table7. S/N ratio of casting porosity pooled ANOVA
FACTOR DEGREE OF
FREEDOM
SUM OF
SQUARES
MEAN SQUARE = SUM
OF SQUARE/ DEGREE
OF FREEDOM
F - RATIO P×100 %
A
B
C
D
TOTAL
(ERROR)POOL
2
2
2
2
8
4
0.128501*
0.422034*
0.559191
0.85954
0
1.969266
0.0642525
0.211017
0.2795955
0.429
0
1.969266
0.466
1.533
2.031
3.122
6.5
21.43
28.39
43.64
100.00
Table 8. Casting porosity pooled ANOVA
FACTOR DEGREE OF
FREEDOM
SUM OF
SQUARES
MEAN SQUARE = SUM OF
SQUARE/ DEGREE OF
FREEDOM
F - RATIO P×100%
A
B
C
D
TOTAL
(ERROR)POOL
2
2
2
2
8
4
0.000066
0.000207
0.000267
0.000396
0.000936
0.0015
0.000033
0.000104
0.000134
0.000198
0.000117
0.000375
0.088
0.277
0.357
0.528
7.05
22.11
28.52
42.30
100.00
In order to study the parameter significance, ANOVA was performed in Table 7 of the S/N ratio. From
Table 7 it is seen that the injection pressure (parameter D) significantly affect the mean average of S/N ratio of
43.64%. Also, the first phase speed (parameter A), second phase speed (Parameter B) and first phase length
5. Study of effect of process parameter setting on porosity levels of aluminium pressure die casting
www.iosrjournals.org 16 | Page
(parameter C) affect S/N ratio of 6.5, 21.43, 28.39, percentage respectively. Table 8 presents an ANOVA of
mean average casting porosity for same parameters. From Table 8 it is proved that the same parameters (A, B, C
and D) significantly affect the variability in S/N ratio of 7.05, 22.11, 28.52, and 42.30 percentage respectively.
III. Estimation of predicted mean
At the optimum setting condition, the casting porosity values were estimated from the following
equation.[3](3) (3) (5)
Predicted casting porosity:
Where Fp is the F – ratio of factor P. parameters represent the best condition of experiments.
The is the overall β – factor which is defined as
Where T is the sum square (ss) and is the variance due to error. From Tables 3 to 8 it can be represented that
M = 0.177 percentage for casting porosity.
T = 0.000936 and = 0.000375. Therefore, the predicted mean estimation of casting porosity is calculated
IV. Estimation of predicted confidence interval
Confidence interval (CI) of the above predicted estimation can be calculated taking into account the
following equation [24]
CI =
Where = F ratio
α = risk (0.05) confidence = 1 α. Therefore for the casting porosity the confidence interval is 95%
= dof for mean which is always = 1
= dof for error, = 0.000375
= number of testes under that condition using the participating factors..
= = = 1
CI = = 0.00866
Therefore the confidence interval is computed as CI = 0.00866. The 95 percentage confidence interval
of the predicted optimum is
[μ - CI] < μ < [μ + CI] ≈ 0.05385 < 0.0625 < 0.07116
V. Confirmation Experiments
Three confirmation tests were conducted at the optimum setting of the process parameters as
recommended by the investigation. The average value of casting porosity obtained at the optimum setting of die
casting parameters was found to be within the predicted confidence interval of the casting porosity.
VI. Conclusion
The following conclusions were drawn from the present investigation. The experimental procedure
showed that the first phase speed, second phase sped, first phase length and injection pressure are the influential
parameters affecting the casting porosity ally SAE 308. Consequently the higher level of injection pressure 270
kg/cm² has the most significant effecting. This was expected because the injection pressure stage of the die
casting procedure is more significant than others, as confirmed by literature and experimentation. The predicted
mean estimation of casting porosity was calculated as 0.0625 percentages with a confidence interval of
6. Study of effect of process parameter setting on porosity levels of aluminium pressure die casting
www.iosrjournals.org 17 | Page
between0.05384 and 0.0.07116 percentages. The results are valid within the above range of process parameters
and for the specified SAE 308 alloy casting.
Acknowledgements
The authors wish to thank Tyche die Cast Company for the use of its industrial installations and
equipments.
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