Multi response optimization of pressure die casting a413 alloy using desirability and genetic algorithm approach

Abstract

Aluminum alloys are commonly used as a material in die casting process throughout the world. In this work A413 aluminum alloy is a material used for this research material for pressure die casting process since A413 aluminum alloy has an excellent performance in automotive industries. It has specific casting characteristics that make it useful for intricate components such as pressure vessels, hydraulic cylinders, and automotive engines, etc. In recent years, several industries are strived to manufacture defect-free components due to huge competition in the market. Thus the entire process of casting has become automated to produce a component economically. It is vital to produce a component with high tolerances and accuracy. In the manufacturing process, machining is a key process to modify the casting components to attain a good surface finish. Milling is a central machining process used to achieve a desired shape and size for complex profiles. It has been observed from the literature review that several researchers reported that pressure die casting has numerous benefits in the casting industry. Still, some of the definite disadvantages are observed in the pressure die casting process. The pressure die casting process is mainly varied from all other casting processes due to its variation in the application of external pressure and solidification process. In the present scenario, demand is increased higher; thus, the process of the casting industry becomes entirely automated to achieve higher productivity. Several research works reveal that the concentration on achieving higher productivity alone leads to compromise the mechanical properties and surface integrity of casting components. Even the casting industry becomes automated, and there is still a problem in the selection of casting process parameters. The improper selection of casting process parameters leads to an increase in the porosity, and it affects the mechanical properties as well as surface integrity. Thus the proper selection of casting process parameters becomes a concern over mechanical properties and surface finish. Several research works reveal that the concentration on achieving higher productivity alone leads to compromise with mechanical properties and surface integrity of the machined surface. Even the machining process becomes automated; still, there is a problem in the selection of machining process parameters newline