• Nikhil Nandha
• Shobha N S

The main purpose of this work is to analyze and determine the type of defects occurring in the die casting process. In any die casting process, porosity is a very serious problem faced by the Production Planning Committee and also being an impregnable defect, it is not identified visually through naked eyes. Porosity formation limits the use of die-cast parts in applications which requires high strength. Porosity rejections account for 40% of the total rejections. To analyze the causes and remedies relating to the defects and to reduce the porosity formation Design of Experiments (DoE) is carried out. Quality tools such as fishbone or Ishikawa diagrams and pareto charts were used to analyze and scrutinize the causes for the defects. The optimal setting of the parameters and the subsequent effect of the selected parameters on the porosity formation was accomplished using Taguchi method. The final results indicated that the critical parameters selected considerably affected the porosity formation in aluminium alloy die castings. Design of Experiments (DoE) was performed with the use of Minitab software. The optimal setting of parameters was found at level 2 of all the factors. The predicted value of density for the optimal setting of parameters was found to be 2.62169 g/cm³ and when compared to its standard value, the porosity percentage was reduced to 2.9% from almost 4%.

High pressure die casting, Design of Experiments, Taguchi method

"Continuous improvement of quality at die casting plant", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.8, Issue 7, page no.c74-c82, July-2021, Available :http://www.jetir.org/papers/JETIR2107274.pdf

"Continuous improvement of quality at die casting plant", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.8, Issue 7, page no. ppc74-c82, July-2021, Available at : http://www.jetir.org/papers/JETIR2107274.pdf