Taguchi Method Calculation & Analysis

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It explains concept of Taguchi method with simple example.

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  • Problem Definition
  • Objectives
  • Introduction of Gravity Die Casting
  • Literature Review
  • Concluding Remarks
  • Scope of Work
  • Methodology
  • Parameters and Levels
  • Technical Specification
  • Chemical Composition
  • Solid Modeling of Shell Core Drum
  • Meshing of Shell Core Drum
  • Comparison of FE Analysis and Experimental Result
  • Steps in Taguchi Method
  • Conformal Analysis
  • Conclusion
  • Scope of Future Work
  • Work Plan
  • Company Profile
  • References
  • Publications
  • Acknowledgment

Parametric Optimization of Gravity Die Casting

Process Using
FEA DOE Hybrid Modeling

Prepared By:
Mr. Ankit D. Oza
M. E. Production Engineering
(En. No. 110300728014)
L. D. R. P. I.T.R.
Gandhinagar - 382015
Gujarat, INDIA
10/20/15

Guided By:
Prof. Tushar M. Patel
Associate Professor
Mechanical Engineering Depart.
L. D. R. P. I.T.R
Gandhinagar - 382015
Gujarat, INDIA
1

Contents

Problem Definition
Objectives
Introduction of Gravity Die Casting
Literature Review
Concluding Remarks
Scope of Work
Methodology
Parameters and Levels
Technical Specification
Chemical Composition
Modeling of Shell Core Drum
Comparison of FE analysis and Experimental result (Validation)
FE analysis using ProCAST
DOE Method (Taguchi Method)
Conformal Analysis
Conclusion
Scope of Future Work
Work Plan
Company Profile
References
Publications

10/20/15

Problem Definition
Case of Gravity die casting of
shell core drum:

To resolve casting defects


after solidification is quite
difficult.
Large number of defects such
as porosity, blowholes.
Higher rate of rejection of
cast component.
Poor productivity.

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Objectives
To minimize the defect like porosity, blowholes etc.
To generate optimum design for gating, runner, riser systems.
To improve the dimensional stability and overall quality of
casting.
To minimize the rejection rate.
To improve the productivity.
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Introduction of Gravity Die - Casting


Gravity die casting is a manufacturing process for producing accurately
dimensioned, sharply defined, smooth or textured-surface metal parts. Gravity die
casting is a simple casting process which utilizes reusable metallic mould. It is
mostly suited to casting light alloys but can also be used for steel and cast irons.

schematic diagram of gravity die casting


10/20/15

Introduction of Gravity Die Casting


Advantages:

Good surface texture.


Equipment costs are relatively low.
No need for applied pressure, so mould designs tend to be quite simple.
Scrap metal can be recycled.
Quick set up times.
To achieve a mass production with better reproduction.
Castings ranging from few grams to 100 Kg of Aluminium alloy can be
cast.
The GDC process is capable of achieving 20% higher mechanical
properties than that of a sand casting because of faster rate of
solidification imparting better grain size.

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Introduction of Gravity Die Casting


Disadvantages:
High percentage of scrap metal.
High cost and time consuming for machining operation.
High occurrence of porosity, but this can be minimized by slower
pouring.
Only good for simple 3D shapes.

10/20/15

Literature Review
Title
Optimized Design of Gating/Riser System in Casting Based on CAD and Simulation Technology
Author (Paper 01)
Feng Liu
Observation
A foundry can produce the best quality molds, cores and molten aluminum and still end up with a poor
quality casting by using poorly designed gating and riser systems.
By using parametric modeling technology by varying each parameter, it is easy to get different casting
CAD models.
Based on the predefined optimization objectives of runner and riser, the range analysis method is also
used to analyze the simulation result and obtain the optimized runner and risers parameters.
Title
Mold Filling Simulation for Predicting Gas Porosity
Author (Paper 02)
Kimatsuka Akihiko, Kuroki Yasunori
Observation
This paper presents a method to simulate mould filling while considering the backpressure and gas
escape.
The governing discrete equations for the momentum and mass conservation laws were derived by the
DFDM (Direct-Finite-Difference-Method). Simulated mould filling patterns agreed rather well with the
results directly observed by X-ray apparatus.
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Title
Stress and Fatigue Analysis in Die casting
Author (Paper 03)
Marco Aloe, Calcom ESI, Switzerland Mark Samonds
Observation
In casting Process Gating systems, overflows, venting channels can be optimized
using CAD software.
ProCAST readily addresses all these issues but also includes advanced features to better assess the
casting quality.
The generalization of CAD modelling and the increase in performance of computers now allows for
these technologies to be applied by the casting industry to full industrial applications.

Title
Modeling of Laser Contour welding process using FEA and DOE
Author (Paper 04)
Bappa acheree, dipen misra, souren mitra
Observation
laser transmission contour-welding process is carried out using finite element analysis (FEA) and design
of experiments (DoE) techniques.
Central composite design of experiments is employed to plan the experimental matrix.
The results of analysis provided the information about the critical parameters, which should be
controlled most precisely.

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Title
Novel methodology for casting process optimization using Gaussian process
regression and genetic algorithm
Author(Paper 05)
Yao Weixiong, Yang Yi and Zeng Bin
Observation
The design of experiment (doe) for simulation is employed to select the most
characteristic process conditions to enrich the information for the model, while to
minimize the time for sample.
Title
Optimization of squeeze casting process parameters using Taguchi analysis
Author (Paper 06)
P. Vijian. V. P. Arunachalam
Observation
Taguchis off-line quality control method was applied to determine the optimal
process
parameters which maximize the mechanical properties of squeeze cast
LM24 aluminum alloy.

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Title
Design OF Experiments For The Pressure Die Casting Process
Author (Paper 07)
Vaclav trobach
Observation
By using Design of experiment method for the preparation of the experiment, a saving
time in the production and a reduction of the direct costs spent on an accidental search
of the optimal parameters.
Title
Experimental and Theoretical Studies on the Effect of Die Temperature on the Quality
of the Products in High-Pressure Die-Casting Process.
Author (Paper 08)
Mohammad Sadeghi and Jafar Mahmoudi
Observation
ProCAST software was used to simulate the fluid flow and solidification step of the
part, and the results were verified by experimental measurements.
By using ProCAST software the Determination of optimized places of overflows by
simulation led to decrease of some casting defects such as cold shots and air
porosities..
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Title
Gravity Die Casting Process Die Design and Process Optimization
Author (Paper 09)
[Link], [Link], Manjunatha, Badrinath
Observation
In gravity die casting of Aluminium parts, computer simulation can be a
useful tool for rapid process development. Limitation of the conventional
die design and gating design has been elaborated.
Title
Flow modeling in casting processes
Author (Paper 10)
Paul Cleary, Joseph Ha, Vladimir Alguine, Thang Nguyen
Observation
Methodology for three-dimensional industrial SPH modeling involves the
CAD specification of die geometry, the construction of FEM meshes using
commercial mesh generators and the conversion of this to SPH input data.
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Title
Design Element Concept of Squeeze casting Process
Author (Paper 11)
[Link], D.T. Gethin, R.W. Lewis
Observation
A finite element model was built and experimentally validated. The models developed
using finite element analysis (FEA) and RSM was found to be educated. The factors effect
and their interactions on the three responses were determined and discussed.
Title
Optimal riser design in sand casting process with evolutionary topology optimization
Author (Paper 12)
R. Tavakoli, P. Davami
Observation
The riser topology is systematically modified to minimize the riser volume, while
simultaneously ensuring that no defect appears in the product. In this approach, we
combine finite-difference analysis of the solidification process with evolutionary topology
optimization to systematically improve the feeding system design.
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Concluding Remarks
From critical literature review it is concluded that there is wide
applicability of finite element analysis and design of
experiment method in the field of gravity die casting which
solves the difficulty of defected cast component and improves
the quality of final solidified cast component.

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Scope of Work
To Remove the Blow holes by Changing
runner & Riser Location & Size
To Modifying Die Design
To Modifying Core Design

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Methodology

Data collection by conventional experiment.


Modeling of the object (With runner and riser).
FE analysis using Pro-CAST.
Comparison of FE analysis with experimental result
(validation).
Optimize of parameter with DOE FEA hybrid modeling.
Modeling using optimum parameter.
FE analysis of optimum model.
Validation of optimum model.

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Parameters & Levels


Major there are three parameters we are taking.
1) Riser Height
2) Runner Height
3) Runner Width
Riser Height
(mm)

Runner Height
(mm)

Runner Width
(mm)

70

111

43

75

113

45

80

115

47

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Technical Specification
Sr. No

Parameter

Specification

Weight

6.9 Kg

Material

Aluminium LM 6

Material Composition

Copper, Magnesium ,Silicon,


Iron, Manganese, Nickel, Zinc,
Lead, Tin, Titanium,
Aluminium Remainder

Pouring Time

10 Sec

Density (g/cm3)

2.65

Co-efficient of Thermal Expansion (Per C at 20-100 C)

0.000020

Thermal Conductivity (Cal/cm2/cm/C/ at 25C)

0.34

Solidification Shrinkage (approx. %)

3.7

Freezing Range (C approx.)

575 - 565

10

Runner -Riser total weight

3.2 Kg

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Chemical Composition

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Sr. No

Alloying Element

% By Weight

Copper

0.1

Magnesium

0.10

Silicon

10.0 - 13.0

Iron

0.6

Manganese

0.5

Nickel

0.1

Zinc

0.1

Lead

0.1

Tin

0.05

10

Titanium

0.2

11

Aluminium

remainder
19

Solid Modeling of Shell Core Drum

The modeling has been performed on the Solid works 2009 version and then after the
analysis work has been performed on the ProCAST.
Solid works is a computer graphics system for modeling various mechanical designs for
performing related design and manufacturing operations. The system uses a 3D solid
modeling system as the core, and applies the feature base parametric modeling method. In
short solid works is a feature based parametric solid modeling system with many extended
design and manufacturing applications.

Features of Solid Works


1) Ease of use
2) Change management
3) Full associatively
4) Hardware independence
5) Parametric & feature based modeling
6) Part design
7) Assembly design
8) Powerful assembly capabilities
9) Design documentation (drawings)
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Modelling of Aluminium Die Cast Component is performed using Solid works


2009

Fig. 3 D Models of Shell Core Drum


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Fig. Core

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Fig. Core & Drum

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Fig. Cross Section of Drum


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Fig. Die
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Fig. Die & Casting


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Drum With Riser and Riser

Fig. Drum with riser and runner


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Wire Boundary

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Fig. Wire Boundary

26

Riser Design

Fig. Riser Design


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Die Design

Fig. Die Design


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Part Drawing

Fig. Part Drawing


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Meshing of Shell Core Drum

Introduction of MeshCAST

MeshCAST generates a 3-D tetrahedral mesh using the Finite Element Method
(FEM). A triangular surface mesh of the object is the prerequisite for MeshCAST's "tet
mesh" generation. Based upon your IGES, PARASOLIDS, STEP, or STL model,
MeshCAST can generate the triangular surface mesh. Alternatively, MeshCAST can
use the surface mesh from your CAD or CAE package as input for tet mesh generation.
MeshCAST is a powerful engineering, design and analytical tool. Some of the
features which contribute to the strength of MeshCAST include:
1) Flexibility
2) Rapid mesh generation
3) Robust repair and manipulation tools
4) Extensive model checking
5) The ability to process and produce a variety of input and output file formats

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based upon the type of input file which was loaded, you perform only the steps
required to continue the development process

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Fig. Meshing In MESHCAST

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PRE Processing in PRE-CAST


1) Import meshing file in PRE CAST

Fig. Import Meshing File in PRE-CAST

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2) Apply cast material as Aluminium Alloy
.

Fig. Aluminium Die Cast Component

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3) Apply interface between mould and Casting

Fig. Interface between Mould and Casting

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4) Apply Air cooling to all mould surfaces

Fig. Apply Air Cooling

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5) Apply inlet velocity to pouring cup.

Fig. Apply Inlet Velocity

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6) Apply inlet temperature to Pouring Cup.

Fig. Apply inlet temperature

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7) Apply Initial Condition for Mould

Fig. Apply Mould Initial Temperature

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8) Apply Initial Condition for Casting

Fig. Apply Aluminium Casting Initial Temperatures

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9) Define Run Parameter for Aluminium Die Casting Simulation.

Fig. Apply Solver Parameters

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Comparison of FE analysis and experimental result (validation)


1) Temperature Contours

Fig. Temperature Contours

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2) Initial When Fluid is poured in Mould

Fig. Initial Pouring

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3) Solidification After 2.0152 Sec

Fig. Solidification after 2.0152 Sec

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4) Solidification After 3.1327 Sec

Fig. Solidification after 3.1327 Sec

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Conti
5) Cross Section View After 3.1327 Sec

Fig. C/s of part after 3.1327 sec

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Conti..
6) Solidification After 4.973 Sec

Fig. Solidification after 4.973 Sec

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7) Cross Section View After 4.973 Sec

Fig. C/s of Part after 4.973 Sec

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8) Solidification After 7.473 Sec

Fig. Solidification After 7.473 Sec

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9) Cross Section View After 7.473 Sec

Fig. C/s of Part after 7.473Sec

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10) Solidification After 8.977 Sec

Fig. Solidification After 8.977 Sec


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11) Solidification Time Contour After 9.973 Sec

Fig. Solidification Time Contour

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12) Fraction Solid Contours After 9.973 Sec

Fig. Fraction Solid Contours

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13) Shrinkage Porosity Contour

Fig. shrinkage Porosity Contour

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14) Temperature V/s Time Plot at different nodal Points

Fig. Temperature V/s Time Plot


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Experimental Procedure:
Tool Maker Microscope used to measure the location as well as size of
porosity

Fig. Tool Maker Microscope


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Put the work piece on the table of microscope.


set the lens of microscope at starting of defect.
start the light and rotate the table as per the defect geometry.
Rotate the screw of table as per defect.
Get the result.

Tool Maker Microscope automatically generates the graph of defect as well as the
perfect location of defect with respect to X-Y-Z axis.
By Measuring Porosity Location and size in Microscope we get the nearer result
as in ProCAST.

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Fig. Comparison Between Experimental Result and ProCAST Result


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Experimental results are taken by using Tool Maker Microscope we get the
% of porosity is 12.30% and in FE Analysis by using ProCAST we get the
% of Porosity is 13.86% as shown in table.

Parameter

Experimental
Result

ProCast Result

Percentage
variation

Porosity %

12.30%

13.86%

0.126%

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Design of Experiment
Runner
Sr.
Riser Height Runner Height
% of
Width
No.
By applying(mm)
DOE method in our result
we get the
(mm)
Porosity
(mm)
%
1 Riser Height
70 Runner Height
111 Runner Width
43 Porosity 11.2
2

70

70

4
5
6
7

70
75
75
75

70
70
75
75
75

111
113
115
111
113
115

113
115
111
113
115

43
45
47
45
47
43

45
47
45
47
43

11.2 12.3
12.3
13.2

13.2
10.4
8.1
12.4

10.4
8.1
12.4

80

80

111

111

47

47

80

80

113

113

43

43

12.1412.14

80

80

115

115

45

45

12.7412.74

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9.8

9.8

60

FE Analysis of Drum Using ProCAST

Modification 1
Riser Height : 70 mm Runner Height : 111 Runner Width : 43

Fig. % of Porosity is 11.2

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Conti

Modification 2
Riser Height : 70 mm Runner Height : 113 Runner Width : 45

Fig. % of Porosity is 12.3

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Modification 3
Riser Height : 70 mm Runner Height : 115 Runner Width : 47

Fig. % of Porosity is 13.2


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Modification 4
Riser Height : 75 mm Runner Height : 111 Runner Width : 45

Fig. % of Porosity is 10.4


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Conti

Modification 5
Riser Height : 75 mm Runner Height : 113 Runner Width : 47

Fig. % of Porosity is 8.1


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Modification 6
Riser Height : 75 mm Runner Height : 115 Runner Width : 43

Fig. % of Porosity is 12.4

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Conti

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Modification 7
Riser Height : 80 mm Runner Height : 111 Runner Width : 47

Fig. % of Porosity is 9.8

67

Conti

Modification 8
Riser Height : 80 mm Runner Height : 113 Runner Width : 43

Fig. % of Porosity is 12.14


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Modification 9
Riser Height : 80 mm Runner Height : 115 Runner Width : 45

Fig. % of Porosity is 12.74


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Steps in Taguchi Method

Formulation of the problem the success of any experiment is dependent on a full


understanding of the nature of the problem.
Identification of the output performance characteristics most relevant to the
problem.
Identification of control factors, noise factors and signal factors (if any). Control
factors are those which can be controlled under normal production conditions.
Noise factors are those which are either too difficult or too expensive to control
under normal production conditions. Signal factors are those which affect the mean
performance of the process.
Selection of factor levels, possible interactions and the degrees of freedom
associated with each factor and the interaction effects.
Design of an appropriate Orthogonal Array (OA).
Preparation of the experiment.
Running of the experiment with appropriate data collection.
Statistical analysis and interpretation of experimental results.

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Signal To Noise Ratio (S/N ratio)

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Conti

This technique helps in data analysis and prediction of optimum results. In


order to evaluate optimal parameter settings, Taguchi method uses a
statistical measure of performance called signal-to-noise ratio. The S/N
ratio takes both the mean and the variability into account. The S/N ratio is
the ratio of the mean (Signal) to the standard deviation (Noise). The ratio
depends on the quality characteristics of the product/process to be
optimized. The standard S/N ratios generally used are as follows:
o Nominal-is-Best (NB)
o Lower-the-better (LB)
o Higher- the- Better (HB).

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Orthogonal Array
Sr.
No.

Riser Height
(mm)

Runner Height
(mm)

Runner Width
(mm)

70

111

43

70

113

45

70

115

47

75

111

45

75

113

47

75

115

43

80

111

47

80

113

43

80

115

45

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Experimental Result table


Sr. No

Riser Height
(mm)

Runner
Height
(mm)

Runner
Width
(mm)

% of
Porosity

70

111

43

11.2

70

113

45

12.3

70

115

47

13.2

75

111

45

10.4

75

113

47

8.1

75

115

43

12.4

80

111

47

9.8

80

113

43

12.14

80

115

45

12.74

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Experimental Result Analysis For


% of Porosity

By using Mini Tab 16 we analyze the result

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Mean Effect Plot for S/N Ratio

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Main Effects Plot For Mean

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Response Table For Mean


Level

Riser Height

Runner Height

Runner Width

12.23

10.47

11.91

10.30

10.85

11.81

11.56

12.78

10.37

Delta

1.93

2.31

1.55

Rank

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Response Table For Signal To Noise


Ratio
Level

Riser Height

Runner Height

Runner Width

-21.73

-20.38

-21.51

-20.13

-20.55

-21.41

-21.20

-22.13

-20.14

Delta

1.61

1.74

1.38

Rank

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Optimum Set of Parameter For


% Of Porosity

Factors levels for Prediction are


Sr. No

Riser Height

Runner
Height

Runner
Width

75

111

47

From level of prediction S/N ratio and Mean value are


-18.6036, 8.40444 respectively

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Conformal Analysis
The optimum set of porosity is riser height 75 mm, runner
height 111 mm and runner width 47 mm is obtained by taguchi
method. So now for validation of optimum set we applied
these values into ProCAST and obtain the result of set as
shown in table
Sr. No

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Riser Height

Runner Height

Runner Width

(mm)

(mm)

(mm)

75

111

47

% of Porosity

8.4902

81

By using ProCAST software we get a value of %


Porosity is 8.4902. This result is quite nearer to our
mean value. Figure shows the % of porosity of
optimum set.

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82

Conclusion
The Taguchis approach has been carried out for optimizing the
parameters of shell core drum. Three input parameters have been
optimized using SNR. The smaller-the-better quality characteristic has
been used for minimizing the porosity of the drum. An L 9 orthogonal array
with three parameters and three levels has been used for predict set of
parameter which gives value of predicated porosity. 9 numbers of
experiments were done for those sets of parameters. Experimental values
of performance were put in the Minitab software16 and software
predicated porosity is 8.4044 % for set of runner height 111 mm, riser
height 75 mm and runner width 47 mm. This suggested set of parameter
which gives optimum performance of porosity. Validation experiment was
done for that set of parameter and compared with predicated value. This
experimental value of % of porosity is very closer to the predicated
values.
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Result obtained from validation experiments using optimum


parameter combination gives excellent agreement with
predicated results.
The performance of the optimized model is better than the
original model and also prove that taguchi parameter design
concept is more powerful and efficient tool for minimize the
porosity.
The FEA based taguchi methods have effectively decrease the
time and efforts required for evaluating the design variables.

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Scope of Future Work


In our thesis work, we optimized parameters for porosity by
applying FEA-DOE method.
By this method, we will optimize other parameters which were not
used in this experiment for porosity.
This method will be also used for other cast product.
This method will be also used for any casting process.
This experiment will be done for same porosity by other DOE
method or other optimization techniques.
Gating/riser Optimization used orthogonal matrix and range to
optimize the gating and riser design. Other optimization methods
may be explored; one runner and riser shape currently used was
analyzed. Other shapes should be explored .
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Work Plan

Work Plan for Various Stages Including Dissertation Phase I


and Phase II
Monthly activity

July

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

June

201

201

201

201

201

201

201

201

201

201

201

201

2
Work Done
Problem

Discussion
Thesis

Writing
Submission &

Definition
Literature
survey
Remaining work
Result and

Defense

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86

Company Profile

Company Profile:
Company Name : Mehtex Engineering Pvt. Ltd.
Company Details: Mehtex Eng. Pvt. Ltd. for last 24 years is serving many
industries with its quality Die Castings. Among the long list of Die Castings a company
has its own Products used in Textiles Processing Machinery, and Automobile parts.

Mehtex Eng. Pvt. Ltd. Has Annual capacity of manufacturing nearly 40,000 end rings
and thus claims to be the only manufacturers to have 17 types of Endrings in India for
export market. To name some of the few we have stork, laxmi, Harish, Zimmer,
Brusher, Reggiani and many more in repeat sizes of 640 to 914 repeat.

The company has also developed lot of Non-Standard Auto- Parts as per clients
Requirements in Domestic as well as International Market.

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Conti

Address of Company: Plot no- 79/3, Phase II, G.I.D.C. Estate,


Naroda , Ahmadabad 382330, India
Email: mehtexcastings@[Link],
Ph. no: +91-79-22823554,
Fax: +91-79-228023924

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References
[1] Feng Liu Optimized Design of Gating/Riser System in Casting Based on CAD and
Simulation Technology, Worcester Polytechnic Institute, December 2008 approved by Prof.
Yiming (Kevin) Rong, Advisor, Associate Director of Manufacturing and Materials
Engineering,
[2] KIMATSUKA Akihiko, KUROKI Yasunori, Mold Filling Simulation for Predicting Gas
Porosity, Manager, Production Technology Development Department, Production
Engineering Center, Corporate Research & Development Vol.-40, No.-2, 2007
[3] Marco Aloe, Calcom ESI, Switzerland Mark Samonds, ESI Software, France Lorenzo
Valente, ECOTRE sas, Stress and Fatigue Analysis in Die casting Italy
[4] Bappa acheree, dipen misra, souren mitra, Modeling of Laser Contour welding process
using FEA and DOE, Optics & Laser Technology 44 (2012) 12811289. Article history:
Received 16August2011 Received in revised form 21December2011 Accepted
29December2011
Available
online14January2012
April
201.
[Link]/locate/optlastec.
[5] Yao Weixiong, Yang Yi and Zeng Bin, Novel methodology for casting process
optimization using Gaussian process regression and genetic algorithm, (School of
Manufacturing Sci. and Eng., Sichuan University, Chengdu 610065, China) volume 6, no-3.

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[6] P. Vijian. V. P. Arunachalam, Optimization of squeeze casting process parameters using


Taguchi analysis. Int J Adv Manuf Technol. DOI 10.1007/s00170-006-0550-2. Received: 7
March 2005 / Accepted: 10 January 2006 / Published online: 19 April 2006. Springer-Verlag
London Limited 2006
[7] V Aclav Strobach, Design OF Experiments For The Pressure Die Casting Process.
ACTA Technical Corviniensis, bulletin of engineering. Annals of Faculty Engineering
Hunedoara International Journal Of Engineering ISSN: 1584-2665 [print] ISSN: 1584-2673
[CD - Rom] University Polytechnic Timisoara Faculty of Engineering Hunedoara 5, R
EVOLUTIEI 331128 Hunedoara Romania
[8] Mohammad Sadeghi and Jafar Mahmoudi, Experimental and
Theoretical Studies on the Effect of Die Temperature on the Quality of the Products in
High-Pressure Die-Casting Process., Advances in Materials Science and Engineering
Volume 2012, Article ID 434605, 9 pages doi:10.1155/2012/434605. Accepted 20 June 2012
[9] [Link], [Link], Manjunatha, Badrinath Gravity Die Casting Process
Die Design and Process Optimization, Dr. Janagan, Ennore Foundries Limited, Chennai,
ProSIM- AFTC, 326, III Stage IV Block, Basaveshwara Nagar, Bangalore 560079 .

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[10] Paul Cleary , Joseph Ha , Vladimir Alguine , Thang Nguyen, Flow


modeling in casting processes, Applied Mathematical Modeling 26 (2002)
171190 Received 1 December 1999; received in revised form 1 November
2000; accepted 24 April 2001. [Link]/locate/apm, 24 April 2001
[11] [Link], D.T. Gethin, R.W. Lewis, Design Element Concept of Squeeze
casting Process, journal homepage: Applied Mathematical Modeling 36
(2012) [Link]/locate/apm
[12] R. Tavakoli, P. Davami, Optimal riser design in sand casting process
with evolutionary topology optimization Struct Multidisc Optim (2009)
38:205214 DOI 10.1007/s00158-008-0282-z. Received: 23 April 2007 /
Revised: 6 May 2008 / Accepted: 8 June 2008 / Published online: 17 July
2008 Springer-Verlag 2008

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Publications
1) I have Publish a Review paper in International Journal of Emerging Technology And
Advanced Engineering. In December
2012.
(ISSN 22502459(Online), An ISO 9001:2008 Certified Journal).
[Link]
My paper title is A Review of FEA-DOE Hybrid Modeling of Gravity Die Casting
Process.

My paper link is [Link]

2) I have Publish a validation paper in International journal of Application or


Innovation in Engineering & Management. In May 2013.
(ISSN 2319-4847)
[Link]
My paper title is Analysis and Validation of Gravity Die Casting Process using
ProCAST
My paper link is [Link]

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3) My Research paper is Selected in Indian Journal of Applied Research.


And Publish in July 2013.
(ISSN 2249-555)
[Link]
My paper title is Parametric Optimization of Gravity Die Casting Using FEADOE Hybrid Modeling

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Publications

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Fig. Certificate of IJETAE

94

Publications

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Fig. Certificate of IJAIEM

95

Thank
You
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
“Parametric Optimization of Gravity Die Casting 
Process Using
FEA – DOE Hybrid Modeling”
Prepared By:
Contents
• Problem Definition
• Objectives
• Introduction of Gravity Die Casting
• Literature Review
• Concluding Remarks
• S
Problem Definition
• Case of Gravity die casting of 
shell core drum:
• To resolve casting defects 
after solidification is q
Objectives
• To minimize the defect like porosity, blowholes etc.
• To generate optimum design for gating, runner, riser syst
Introduction of Gravity Die -  Casting
•
Gravity die casting is a manufacturing process for producing accurately 
dimensioned
Introduction of Gravity Die Casting
Advantages:
– Good surface texture. 
– Equipment costs are relatively low. 
– No need fo
Introduction of Gravity Die Casting
Disadvantages:
– High percentage of scrap metal. 
– High cost and time consuming for mac
Literature Review
Title
“Optimized Design of Gating/Riser System in Casting Based on CAD and Simulation Technology”
Author (P
Title
“Stress and Fatigue Analysis in Die casting”
Author (Paper 03)
Marco Aloe, Calcom ESI, Switzerland Mark Samonds
Observa
Title
“Novel methodology for casting process optimization using Gaussian process 
regression and genetic algorithm”
Author(Pa

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