Numerical Optimization of Gating System for an Aluminum Casting based on the Taguchi method with Multiple Performance haracteristics

摘要

The design of gating system for castings has been mostly based on empirical rules and past experience. A number of studies have been carried out on the gating system design by trial and error method. However, very few have focused on the numerical optimization of the gating system process parameters. In this study, gating systems with various parameters for a sand cast test plate of aluminium alloy A356 were designed. Mold filling and solidification processes of the plat casting were simulated with the MAGMASOFT?. The predicted results indicate that gating system parameters, I.e. ingate height, ingate width, runner area, and choke diameter significantly affect the quality of casting. In an effort of determining the optimal process parameters of gating system, the Taguchi method, a powerful design of experiment (DOE) technique, was employed. An orthogonal array, the signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) were used to analyze the effect of various gating designs on cavity filling and casting quality with multiple performance characteristics using a weighting method.