Design and optimisation of die casting process for heavy-duty automatic transmission oil circuit board

ABSTRACT In this study, HPDC is introduced into the production of oil circuit board, aiming to solve forming defects and provide a complete design concept for the exploitation of die-casting process in large castings. First, the die-casting die was designed and its rationality was verified, but the unreasonable selection of injection process parameters caused casting non-conformance. Next, the experimental data of L25 orthogonal array of Taguchi method were used as training samples and the porosity of the die-cast part was examined in relation to casting variable parameters. Specifically, the velocity, temperature and injection pressure were mainly investigated, while the mathematical model passed the test of accuracy. Finally, Particle Swarm Optimisation (PSO) algorithm was used to optimise the model, achieving minimum porosity. The results have shown that the PSO algorithm optimisation results are better than the one produced by the Taguchi method, providing a significant improvement over the pre-optimisation results.