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Title: Evaluating the Effects of Process Parameters in Cold Chamber High Pressure Die Casting
Authors: Upneja, Virender
Supervisor: Kumar, Vinod
Kumar, Lalit
Keywords: Cold Chamber HPDC;Microstructure
Issue Date: 28-Mar-2013
Abstract: High Pressure Die Casting (HPDC) is an efficient, economical process offering a broader range of shapes and components than many other manufacturing techniques. High Pressure Die Casting is a process by which a molten non-ferrous material is forced under high pressure into reusable tool steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability, with smooth or textured surfaces. High Pressure Die Casting is best suited for high volume production runs and can produce the least expensive parts. A variety of materials are available for the High Pressure Die Casting process. The included materials and process charts can be used to help determine which are best suited for a specific application. Experiments in industrial environment were conducted producing wire clamp using commercially treated A356 (Al-Si) and ADC 12 (Al-Si) alloy. The different process parameter were varied such as injection pressure, pouring temperature, coating type, cooling type to understand their affect on the final product. The objective of this study is to evaluate the main effects i.e. thermal characteristics (temperature of the molten metal), injection pressure of the molten metal, type of coating (oil coating, oil + graphite coating, Dycot coating), and the type of cooling (air cooling, water cooling and oil cooling) on density of the material, hardness of the material and the surface roughness of the material. The methodology used to calculate the effect of various parameters will also be studied using parameterization approach in design of experiment is Taguchi approach.Taguchi’s approach provides a powerful and efficient method for designing products that operate consistently and optimally over a variety of conditions This approach allows quality considerations to be included at an early stage of any new venture; in the design phase for a product, during routine maintenance or during installation of a manufacturing process An experimental model for Multi Response Signal To Noise (MRSN) ratio encompassing three responses namely surface roughness, density and hardness has been employed to carry out the experimental study and subsequent analysis. Analysis of Variance (ANOVA) was performed for all the responses and the effect of the factors was explained with the help of main effect plots. Micro structural analysis for all the trials was done. The major finding and conclusion of this research is that control of various parameter such as pouring temperature, injection pressure, coating type cooling type enhances the quality of product and suggest the different combination of process parameter which helps the product to sustain in the market. Some limitation of numerical modelling and metallurgical analysis were also identified during this research and recommendations were made to improve the surface roughness, hardness & density of aluminium alloy wire clamps.
Description: M.E. (Production and Industrial Engineering)
Appears in Collections:Masters Theses@MED

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