Multi-Response Optimization of Die Casting Process for Lock Assembly of a Two Wheeler

Thousands of consumer, commercial, and industrial products can be produced by die casting process with high volume ranging from small to large components and hence die casting can be referred as mass production process. One such component is the lock assembly of a two wheeler which is made of ZAMAK (Zinc alloy) and produced by die casting process. Some of the products produced by die casting was defective and hence needs to improve the performance of the process. The objective of the study was to evaluate the effect of injection pressure of the molten metal, hydraulic pressure, temperature of the molten metal, and the cooling time on the dimensional stability of the lock assembly of two wheeler. In order to study the effect, the process parameters such as injection pressure of the molten metal, hydraulic pressure, temperature of the molten metal, and the cooling time Response Surface Methodology (RSM) with Face Center Design (FCD) was used. The experiments were carried out according to design matrix. Four responses namely slot diameter, pitch circle diameter, pin-hole diameter, and pin-hole depth were used for study. The RSM model was developed for each response. Analysis of variance (ANOVA) for each response was also carried out to find out the significant factors and their interactions. Finally, optimization was carried out and the optimized input parameters were validated by conducting experiments. The modeled and experimental results were compared and an error of 2-7% was observed.