MULTI-OBJECTIVE OPTIMIZATION OF PROCESS PARAMETERS IN GRAVITY CASTING METHOD BY USING INSPIRE CAST

Gravity die casting was one of the very earliest processes to be invented for metal and light alloy die casting. In this process which can be fully automated, the molten metal is poured directly from a ladle into a semi-permanent or permanent die. The goal is to fill the die with minimum turbulence through one or more channels to reduce oxidation and foaming. This minimizes porosity and inclusions, giving optimum metal characteristics in the final casting. Gravity die casting equipment can have a vertical or horizontal mould opening, or tilting technology with 0/90 ° or 0/120 ° tilting provides an alternative. The aim of this project is to perform the Gravity casting process to identify the optimum process parameters. Altair Inspire Cast simulation software is used to perform the casting process in-ordered to identify the optimum process parameters. Taguchi’s Design of experiments method is used to frame the experiments, L09 orthogonal array is used to conduct the casting process. Input parameters like Inlet-position, Number of Raisers, Filling time has taken. The analyzed Output parameters are Filling temperature, cold-shuts, solidification temperature, solidification time, porosity, Total shrinkage volume. Grey Relation Analysis is adopted to perform multi-objective optimization. The results reveal that the optimum condition is Side-inlet, 0 Raisers, 15 seconds filling time.