Optimization of Semi-solid High-Pressure Die Casting Process by Computer Simulation, Taguchi Method and Grey Relational Analysis

The main aim of this research was to simulate high-pressure die casting of A356 semi-solid aluminum alloy using casting process simulation tool. Taking into account the viscosity of the semi-solid slurry and the mold-filling characteristics in high-pressure die casting, the mold for semi-solid aluminum alloy had been designed. Also, the influence of the three input parameters (liquid fraction of slurry, plunger velocity at 2nd phase and mold geometry) on the casting time, shrinkage and bubble formation during semi-solid high-pressure die casting processes were investigated. The Taguchi-based ‘grey relational analysis’ approach was used to identify the optimal process parameters. A method used in this study for finding out the importance of the controllable parameter on the performance characteristic is called the analysis of variance. It was observed that the optimal parameters are the liquid fraction of 50%, the plunger velocity at 2nd phase of 1 m/s and the angle between the vertical plane and the cavity of 60°.