IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 1 Issue 6, August 2014.

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ISSN 2348 – 7968

Optimization Of Process Parameters In Cold Chamber Die Casting

Process Using Taguchi Method
1*
Senthiil, P. V., 2M.Chinnapandian and 3Aakash Sirusshti
1*
Head, Director Advance Manufacturing Technology, Mechanical Engineering, St.Peters University,
Chennai-600054, Tamilnadu, India
2
Head of Aeronautical Engineering, SPCET,Chennai, Tamilnadu, India
3
Department of Mech, SRM University Vadapalani Campus, Chennai, Tamilnadu, India.

Abstract: has been selected for optimization. The response

High Pressure die casting process is a factor (quality characteristic) chosen is density of

process ideally suited to manufacture mass the casting. Density of the casting is chosen as a

produced metallic parts of complex shapes quality characteristic since it has direct

requiring precise dimensions. In this process, relationship with casting defects. Generally

molten metal is forced in to empty cavity of denser the casting lesser the internal defects such

desired shape and is allowed to solidify under as porosity, blow holes etc. Besides all this, final

high holding pressure. Die casting is a complex results were validated by both experimental and

process which is controlled by many parameters casting simulation. [9]

such as die related parameters, machine related 1. Introduction

parameters, which has direct impact on casting
In manufacturing processes, there are
quality. Improper settings of these parameters
various parameters with different adjustment
end up in producing quality related issues in the
levels, which may influence the final
casting. One such issue is blow holes and
characteristics of the product. To optimize a
porosity which is caused by improper setting of
manufacturing process, the trial and error
process parameters. In this paper an industrial
method is used to identify the best parameters to
component having blow hole problem has been
manufacture a quality product. However, this
taken. This study proposes application of
method demands extensive experimental work
Taguchi methodology in identifying the optimum
and results in a great waste of time and money.
process parameters in order to improve the
Thus, optimization methods appear to be an
casting quality. Process parameters such as
important tool for continuous and rapid
holding furnace temperature, slow shot, Fast
improvements. These experimental methods may
shot, Die holding time, Intensification pressure

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be employed to solve problems related to a component has high rejection rate due to the
manufacturing process, and understand the occurrence of blow hole problem. Especially the
influence of various factors on the final quality critical area of the casting shown in Fig.1 has
of a given product. more number of blow hole occurrence compared
to the other areas of the casting. { 4]
The die casting process is controlled by
several parameters. When properly determined
and adjusted, they result in an improvement in
quality of the die casting parts. Usually, the main
controlled variables are metal temperature, slow
shot, and fast shot, intensification pressure, die
holding time, chemical composition of metal.
G.O. Verran et al. (2008) has analysed the effects
of slow shot, Fast shot, and Intensification
Figure.1 Blow holes in ‘Front Wheel Hub I casting’
pressure on casting density. The results indicate
2. Taguchi parameter design
that the injection parameters affect the casting
Taguchi parameter design provides a
density to a greater extent. Similarly V.D.
means of both reducing cost and improving
Tsoukalas (2008) has analysed effects of die
quality by making effective use of experimental
casting process parameters on porosity formation
design methods. This involves the determination
using genetic algorithm. The results reveal that
of parameter values that are least sensitive to
under optimized conditions porosity formation is
noise .When the goal is to design a process or
very less. P. Vijian et al. (2006) has applied
product with high stability and reliability,
Taguchi method for optimizing the parameters in
parameter design is the most important step in
squeeze casting in order to minimize surface
which the functional non linearity is used to best
roughness.
advantage. Initially parameters that are to be
In this study optimization of die casting
optimized are chosen carefully. A cause and
parameters using Taguchi methodology was
effect diagram can be used for identifying the
carried out to solve the blow hole problem in an
parameters that affects the response. In this
aluminium component named ‘ Front Wheel Hub
study, casting density has been chosen as a
I’ . The material is AlSi9MnMg alloy. The

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ISSN 2348 – 7968

response, since if the casting density is higher, validation. The ranges for the selected factors are
lower the internal defects such as blow holes and shown in Table 1.
porosity. A cause and effect diagram drawn for
blow holes in casting is shown in figure 2
Parameters Level Level Level
S.No Parameters Range
Destination 1 2 3
Metal
640-
1 A temperature 640 660 680
680
(°C)
Slow Shot 0.12-
2 B 0.12 0.17 0.22
(m/s) 0.22
Fast shot 1.92-
3 C 1.92 2.17 2.42
(m/s) 2.42
Die holding
4 D time 8-10 8 9 10
(seconds)
Intensification
270-
5 E pressure 270 280 290
2 290
(kg/cm )
Table 1 Selected Factors and their ranges

The selection of orthogonal array

Figure 2 Cause and effect diagram for blow holes
After analyzing the cause and effect diagram,
and checking the various parameters, die casting
machine parameters such as Metal temperature
(A), Slowshot(B), Fast shot(C),Intensification
pressure(D), Die holding time(E), have been
selected for the analysis of the blow hole
problem in casting. Interactions were also
considered between parameters
temperature, slow shot, Fast Shot. The ranges for
the chosen factors were selected based upon
preliminary trials conducted during process
depends upon the degrees of freedom of the
factors and the three interactions that have been
considered. We get 10 degrees of freedom for
five factors at three level and 12 degrees of
freedom for three interactions. Thus smallest
orthogonal array that can be used must have at
least 22 degrees of freedom. Hence from the
standard orthogonal arrays we choose L27
orthogonal array which can accommodate 13
factors and has 26 degrees of freedom. A L27
Orthogonal array is shown below in table 2.
Metal

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Trail No COLUMNS
A B C D E F G H I J K L M
to a temperature of 190°C using a gas burner.
1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 1 1 1 1 2 2 2 2 2 2 2 2 2 The die temperature was measured by using
3 1 1 1 1 3 3 3 3 3 3 3 3 3
4 1 2 2 2 1 1 1 2 2 2 3 3 3
5 1 2 2 2 2 2 2 3 3 3 1 1 1
infrared gun. The molten metal was cleaned by
6 1 2 2 2 3 3 3 1 1 1 2 2 2
7 1 3 3 3 1 1 1 3 3 3 2 2 2 removing the slag to avoid impurities and
8 1 3 3 3 2 2 2 1 1 1 3 3 3
9 1 3 3 3 3 3 3 2 2 2 1 1 1
10 2 1 2 3 1 2 3 1 2 3 1 2 3
degassing was done to remove the hydrogen
11 2 1 2 3 2 3 1 2 3 1 2 3 1
12 2 1 2 3 3 1 2 3 1 2 3 1 2 content. The material composition was checked
13 2 2 3 1 1 2 3 2 3 1 3 1 2
14 2 2 3 1 2 3 1 3 1 2 1 2 3
15 2 2 3 1 3 1 2 1 2 3 2 3 1
by using spectro analysis before starting of the
16 2 3 1 2 1 2 3 3 1 2 2 3 1
17 2 3 1 2 2 3 1 1 2 3 3 1 2 experiment. Initially 50 shots were carried so that
18 2 3 1 2 3 1 2 2 3 1 1 2 3
19 3 1 3 2 1 3 2 1 3 2 1 3 2
20 3 1 3 2 2 1 3 2 1 3 2 1 3
machine gets stabilized to conduct the
21 3 1 3 2 3 2 1 3 2 1 3 2 1
22 3 2 1 3 1 3 2 2 1 3 3 2 1 experiment. A total of 27 different combinations
23 3 2 1 3 2 1 3 3 2 1 1 3 2
24 3 2 1 3 3 2 1 1 3 2 2 1 3
25 3 3 2 1 1 3 2 3 2 1 2 1 3
shown in Table 3 were tried and 3 parts were
26 3 3 2 1 2 1 3 1 3 2 3 2 1
27 3 3 2 1 3 2 1 2 1 3 1 3 2 cast for each combination, which totals to 81
castings. Each casting was given separate
Table 2 L27 Orthogonal array
identification mark to avoid mixing of the
3. Experimental Procedure castings. Finally after completing the
experiment, the castings were trimmed, fettled
The experimental setup consists of die
and cleaned thoroughly. Der Ho et.al (2004)
casting cell comprising of 250T die casting
machine, an electric holding furnace, shot
monitoring system. The die casting machine is
semi-automated, having an auto ladler for
pouring the molten metal from the melting cum
holding furnace. The various settings required
for this experiment can be set manually and it is
monitored through the shot monitoring system.
The shot monitoring system helps us in
monitoring the parameters set so that we can
check its status during each shot. Aman
Agarwal et al. ( 2008). Aman AgarwalBefore
starting the experiment, the dies were preheated

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Metal
Trial.No temperature
Slow shot Fast shot Die holding Intensification thrice in order to avoid any errors. The density of
(B) (C) time (D) pressure (E)
(A)
1 640 0.12 1.92 8 270 the casting were calculated based upon the
2 640 0.12 2.17 9 280

3 640 0.12 2.42 10 290 formula

640 0.17 1.92 9 280
ρ= {w 1 / (w 1 -w 2 )} x ρ water
4
5 640 0.17 2.17 10 290

Where ρ = density of the casting (gm/cm3)

6 640 0.17 2.42 8 270

7 640 0.22 1.92 10 290

8 640 0.22 2.17 8 270

9 640 0.22 2.42 9 280

w 1 = weight of the casting in air (grams)
10 660 0.12 1.92 9 290
660 0.12 2.17 10 270
w 2 = weight of the casting in water (grams)
11

ρ water = density of water (1 gm/cm3)

12 660 0.12 2.42 8 280

13 660 0.17 1.92 10 270

660 0.17 2.17 8 280
14
660 0.17 2.42 9 290
4. Experimental results
15
16 660 0.22 1.92 8 280

17 660 0.22 2.17 9 290

660 0.22 2.42 10 270
The density of the casting was measured
18
680 0.12 1.92 10 280
19
680 0.12 2.17 8 290
by Archimedes principle and the results are
20
680 0.12 2.42 9 270
21
680 0.17 1.92 8 290
shown below. Minitab 14 software has been used
22
680 0.17 2.17 9 270
23 to carry out Taguchi optimization .The response
24 680 0.17 2.42 10 280
680 0.22 1.92 9 270
25 value is taken as average density of the three
26 680 0.22 2.17 10 280

27 680 0.22 2.42 8 290

sample castings that were cast under each trail
condition. Then S/N ratio were computed based
Table 3 Test Run design
upon the formula S/N ratio for larger the better
The density of the castings were
characteristics = -10 log (1/r Σ (1/y i 2)) where r
measured based upon the Archimedes principle.
-number of observations, yi -Response value for
Before measuring the density of the casting, care
each trail. The experimental results are shown in
was taken that casting is completely free from
table 4.
the burr or any dust in order to avoid errors in the
Density (g/cm3) Average
measurement. Belavendram(10). Belavendram S/N Ratio
Sample Sample Sample density
The castings were first weighed in air and then 1 2 3
2.578 2.583 2.584 2.581 8.236
weighed when completely immersed in water.
2.581 2.587 2.587 2.585 8.249
All the weighings were done by using electronic 2.591 2.592 2.592 2.592 8.273
weighing machine having accuracy up to 100 2.584 2.589 2.590 2.587 8.256
2.588 2.592 2.594 2.592 8.273
mg. Ko Ta Chiang et al.(2009). The density
2.578 2.582 2.584 2.581 8.236
measurement of each casting was measured 2.588 2.593 2.595 2.592 8.273
2.577 2.584 2.584 2.582 8.239

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2.582 2.588 2.589 2.586 8.253

2.587 2.592 2.594 2.591 8.269
2.584 2.582 2.586 2.584 8.246
2.581 2.586 2.587 2.585 8.249
2.582 2.587 2.588 2.586 8.253
2.582 2.588 2.589 2.586 8.253
2.585 2.592 2.593 2.590 8.266
2.583 2.589 2.590 2.587 8.256
2.588 2.589 2.594 2.590 8.266
2.574 2.588 2.589 2.584 8.246
2.586 2.591 2.592 2.590 8.266
2.585 2.591 2.592 2.590 8.266
2.579 2.585 2.585 2.583 8.242
2.588 2.593 2.597 2.592 8.273
2.582 2.586 2.588 2.585 8.249
2.585 2.590 2.592 2.589 8.263
2.582 2.588 2.589 2.586 8.253
2.584 2.590 2.591 2.588 8.259
2.586 2.591 2.593 2.590 8.266
Average=2.587 Average=8.256

Table 4 Experimental results

The response table and graphs for mean (casting

density) are shown in table 5 and figure 3.

Table 5 Response table for

Means Figure 3 Response Graphs for Means (casting density)

Intensif
Metal Slow Fast Die The response table and graphs for S/N ratios are
ication
Levels temperature Shot shot holding
pressur
(A) (B) (C) time (D) shown in table 6 and figure 4
e (E)
2.586
1 2.586 2.588 2.586 2.584
7
2.587 2.586
2 2.587 2.587 2.587
5 8
2.587 2.586
3 2.588 2.589 2.591
2 6
Max- 0.000 0.001
0.002 0.003 0.007
Min 8 4
Rank 3 5 4 2 1

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Metal Slow Fast m/s, Fast Shot-1.92 m/s, Die holding time-10
Die holding Intensification
Levels temperatur Shot shot
e (A) (B) (C)
time (D) pressure (E)
seconds, Intensification pressure-290 kgf/cm2
8.25
1
8.254 8.255 9 8.253 8.244
8.25
2
8.256 8.258 6 8.256 8.256 4.1 ANOVA table for Means and S/N Ratios
8.25
3
8.26 8.257 5 8.261 8.269 In order to determine which parameter
Max- 0.003 0.00
0.006 0.008 0.025 significantly affect the quality characteristic
Min 0 4
Rank 3 5 4 2 1
(casting density), ANOVA is done. S.Guharaja

Table 6 Response table for S/N ratio (2009). F tab -value was taken at 95% confidence
interval. The ANOVA table for means and S/N
ratios are shown in table 7 and 8.

Table 7 ANOVA table for Means

F-
SOURCE DF SS MS F-tab P%
CAL
A 2.000 0.000013 0.0000065 13 6.94 4.17

B 2.000 0.000003 0.0000015 3 6.94 0.96

C 2.000 0.000009 0.0000045 9 6.94 2.88

D 2.000 0.000030 0.000015 30 6.94 9.62

E 2.000 0.000250 0.000125 250 6.94 80.13

AXB 4.000 0.000000 0 0 6.39 0.00

AXC 4.000 0.000003 7.5E-07 1.5 6.39 0.96

BXC 4.000 0.000002 0.0000005 1 6.39 0.64

ERROR 4.000 0.000002 0.0000005 0.64

TOTAL 26.000 0.000312 0.000012 100.00

Figure 4 Response graphs for S/N Ratios

From the response graphs the optimized results
are Metal temperature -680°C, Slow shot-0.17

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SOURCE DF SS MS F-CAL F-tab P% where α is the level of risk, v e is the degrees of

A 2
14E-
73E-04 10.81 6.94 4.150 freedom for error, η eff is the effective number of
03
B 2
31E-
155E-04 2.30 6.94 0.881
replications is the number trials taken for
04
2
104E- confirmation test, V e is the error variance
C 52E-04 7.70 6.94 2.956
03
337E- η eff = (Total number of experiments/sum of dof
D 2 1685E-03 24.96 6.94 9.579
03
281E- used in estimate of mean)
E 2 0.001408 208.59 6.94 80.045
02
UsingthevaluesF-
AXB 4 4E-05 0.000001 0.15 6.39 0.114
29E-
ratio(0.05,1,4)=7.71,V e =0.0000005, v e =4,r=3
AXC 4 7.25E-06 1.07 6.39 0.824
04
24E-
Therefore C.I = {7.71*0.0000005*((1/9)+(1/3))}
BXC 4 0.000006 0.89 6.39 0.682
04
= ±0.001308
27E-
ERROR 4 6.75E-06 0.767
04 The 95% confidence interval of the predicted
3518E 0.000135
TOTAL 26 100.000
-02 3 optimum of the casting density is 2.593<µ<2.596
5. Confirmation test
Table 8 ANOVA table for S/N Ratio Finally confirmation test were carried out
at optimized conditions. The average casting
4.2 Prediction of Optimum response density (2.593g/cm3) of three confirmation test
In establishing to what extent the data of samples lies well within the confidence limit.
the experiment is successful, it is necessary to Philip J. Ross(11). The Radiography test was
predict the mean at the optimum condition and carried out on the confirmation test samples and
then compare them against a confirmation the test results revealed no significant defects
experiment. For mean response the overall were found. The Radiography images of
average of casting density (T) is 2.587. The defective sample and confirmation test sample
predicted optimal response (µ) is: are shown in Figure 5.
µ predicted = Estimate of the process mean at
optimum condition
= T+(A3-T)+(C1-T)+(D3-T)+(E3-T)
= 2.595
Estimation of confidence interval (means) for
confirmation experiment is :
C.I= (F(α,1,v e )V e (1/η eff +1/r))1/2

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Defective
Confirmation test sample
Figure 5 Radiography images
Similarly the confirmation test samples were
machined in order to evaluate the critical area.
After machining the critical area were free from
blow holes. The images of critical area machined
are shown in figure 6
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Defective sample Confirmation test sample
Figure 6 Images of critical area machined
6. Regression Analysis
The Multi variable regression equation (MVLR)
sample developed is
Density=2.45+0.000042*A+0.00444*B-
0.002667*C+0.0012778*D+0.000372*E
Where A is Metal Temperature, B is slow shot,
C is Fast shot, D is Die holding time, E is
Intensification pressure
R2 = 0.962 for the MVLR equation developed
for density. Similarly the F cal value (105.88) for
the regression model is greater than F tab (2.68) at
95% of confidence limit.
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Figure 8 Flow analysis

7.2 Solidification analysis

Figure 7 Predicted Vs Actual density values

7. Numerical simulation
The numerical simulation was also done
at the optimized conditions in order to predict
any defects were arising in the casting. The
casting simulation was done by using Z-cast v2.6
trial version. The simulation results consist of
Flow analysis, Solidification analysis, and Defect
analysis. The simulation results are shown
below.
7.1 Flow analysis
Figure 9 Solidification analysis

7.3 Defect analysis

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2) The parameters considered contribute

variation towards casting density. The percentage
of contribution of each factor was calculated by
using ANOVA method. They contribution of
each factor towards casting density and S/N ratio
are shown in the below graph.

Figure 10 Defect analysis

The simulation results also reveal that no defects

were found in the casting. In the defect analysis
simulation defect was found only in the over
flow connector area. The casting simulation
results coincide well with the experimental
Figure 11 Percentage contributions of control
results.
factors
8. Results and discussion 3) The radiography images show that castings

The experiments have been conducted and the that were taken under the optimized conditions

results are summarized as follows: show no defect when compared to the castings

1) The optimized parameters of this experiment that was taken during non-optimized conditions.

are 4) Similarly the confirmation test samples were

• Metal temperature-680ºC machined and the critical area of the casting was
found to be free of blow holes.
• Slow shot-0.17 m/s
5) Simulation results also reveals that under
• Fast shot-1.92 m/s
optimized conditions no defect (blow holes) was
• Die holding time -10 seconds
found in the casting
• Intensification pressure- 290 kg/cm2

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10. Conclusion
The optimization procedure has been
made to study the effect of die casting process
parameters on casting density. Generally when
the casting density is higher, internal defects
such as blow holes and porosity is eliminated.
So, the basic idea is to provide a decision tool for
setting optimum parameters so that the defects
occurring in the casting is reduced.
Taguchi method was applied
optimizing the die casting process parameters,
and the results obtained using this method was
useful in eliminating the blow holes problem in
Front Wheel Hub I casting. At optimized
parameters the casting quality was better than the
previous casting that was cast under the non
optimized conditions. The radiography test
results also revealed that samples cast under the
optimized parameters has no significant defects.
Similarly the results obtained using simulation
software Z-cast V2.6 (Trial version) at optimized
condition shows no presence of defects in
casting. Considering the contribution of the
parameters, intensification pressure was the
factor showing more influence on the casting
density compared to the other parameters.
The outcome of this project work was
very useful for finding solution for casting
defects that occurs due to the incorrect process
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parameters in die casting. Also these results will
help in improving the productivity of Front
Wheel Hub I castings at Roots Cast Private
Limited in future. Thus combination of
optimization techniques along with casting
simulation serves as a tool for improving the
productivity of the castings to a greater extent, in
die casting industries.
References
[1].DOE applied to optimization of aluminum
for alloy die castings by G.O. Verran, R.P.K.
Mendes, L.V.O. Dalla Valentina, , Journal of
Materials Processing Technology, May 2008
[2].Optimization of porosity formation in
AlSi 9 Cu 3 pressure die castings using genetic
algorithm analysis by V.D Tsoukalas , Materials
& Design, December 2008
[3].Use of Taguchi method to develop robust
design for the magnesium alloy die casting
process by Der Ho Wu, Mao Sheng Chang ,
Materials Science and Engineering, August 2004
[4].Modelling and analysis of the effects of
processing parameters on the performance
characteristics in the high pressure die casting
process of Al–SI alloys by Ko-Ta Chiang & Nun-
Ming Liu & Te-Chang Tsai, International
Journal of Advanced Manufacturing Technology
(2009)
[5].Optimization of squeeze cast parameters of
LM6 aluminium alloy for surface roughness
using Taguchi method by P. Vijian, V.P.
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Arunachalam,Journal of Materials Processing
Technology, December 2006
[6].Optimization of Green sand casting process
parameters by using Taguchi’s method by
S.Guharaja, A.Noorul Haq, K.M.Karuppannan,
International Journal of Advanced
Manufacturing Technology (2009)
[7].Optimizing power consumption for CNC
turned parts using response surface methodology
and Taguchi’s technique- by Aman
Agarwal,Hari Singh, Pradeep Kumar,
Manmohan singh , Journal of materials
processing technology ( 2008)
[8].Optimization of high pressure die-casting
process parameters using artificial neural
network by by Jiang Zheng, Qudong Wang,Peng
Zhao, Congbo Wu, International Journal of
Advanced Manufacturing Technology (2009)
[9].Die Casting Engineering by Bill Anderson
[10].Quality by design by Nicole Belavendram,
He did two Bachelor degrees in B. Sc Physics at
Ayya Nadar Janaki Ammal College, M.K.
University, Madurai, and B. Tech Automobile
Engineering at Madras Institute of Technology
(M.I.T) Chrompet Campus, Anna University
Chennai, Master degree in M.E Energy Engineering
at the College of Engineering Guindy, Anna
University Chennai. He received his Ph. D
Mechanical Engineering from College of
Engineering Guindy, Anna University Chennai in
recognizing his significant contribution in the area of
Cascaded Latent Heat Storage System for Diesel
Engine Waste Heat RecoveryPrentice Hall
Publications
ISSN 2348 – 7968
[11].Taguchi techniques for Quality
engineering, by Philip J. Ross, McGraw Hill
Publications.
BioGraphy:
Dr. P.V Senthiil is currently
working as Director(AMT)Prof &
Head, Mechanical Engg at St
Peter's University, Chennai, India.
He lectures modules in CNC
machines, Rapid Prototyping and
AI & Robotics. He is also guiding
10 researchers in different disciplines. His work
experience as a Factory consultant / knowledge
transfer partnership associate working for electronic
goods consumer industry in south Africa, France,
UK. He was involved in developing, implementing &
documenting operating procedures in advanced
applications CNC industries for inventory reduction
activities within various sectors of the company.
Prior to start of his research, Dr Senthiil was working
as a Professor at Coimbatore Institute of Technology
between May 1986 to Jun 2011. He did his masters
in Mechanical Engineering at PSG Tech, April 1985,
Bachelor’s at PSG Tech, in Mechanical Engineering,
April 1983. He is a World Science Academy Council
Member,Visiting Professor – Nottinghamshire
University, Malaysia and Visiting Professor of
Caledonian University, MUSCAT/AIT Bhagdad
Dr M.Chinnapandian is currently working as Prof
& Head, Aeronautical Engg at St Peter's College of
Engg Tech, Chennai, India. He did two Bachelor
degrees in B. Sc Physics at Ayya Nadar Janaki
Ammal College, M.K. University, Madurai, and B.
Tech Automobile Engineering at Madras Institute of
Technology (M.I.T) Chrompet Campus, Anna
University Chennai, Master degree in M.E Energy
Engineering at the College of Engineering Guindy,
Anna University Chennai. He received his Ph. D
Mechanical Engineering from College of
Engineering Guindy, Anna University Chennai in
recognizing his significant contribution in the area of
Cascaded Latent Heat Storage System for Diesel
Engine Waste Heat Recovery.
337