Modeling and Optimization of Die Casting Process for ZAMAK Alloy

Abstract

The objective of the following study was to evaluate the effect of injection pressure of the molten metal, hydraulic pressure, temperature of the molten metal and the cooling time on the dimensional stability of the lock assembly of two wheelers. The material of the lock assembly was ZAMAK 3 (zinc, aluminum, magnesium, and copper) alloy. The lock assembly was produced by die casting process. In order to study the effect the process parameters such as injection pressure of the molten metal, hydraulic pressure, temperature of the molten metal and the cooling time, RSM (response surface methodology) with face center design was used. The experiments were carried out randomly according to design matrix. Three responses (shutter width, shutter thickness and shutter hinge length) were used for study. The RSM model was developed for each response. Analysis of variance for each response was also carried out to find out the significant factors and their interactions. Finally, optimization was carried out and the optimized input parameters were validated by conducting experiments at the optimum input parameters. The modeled and experimental results were compared and an error of 2-8% was observed.