Abstract:The present research work emphasized on identifying and optimizing various significant process parameters of high pressure die casting by using QFD-Taguchi based hybrid approach in order to yield the optimum casting density of the A380 alloy. Identification of critical process parameters, selection of appropriate orthogonal array, analysis of means and analysis of variance are employed to study the performance characteristic of the die casting process. The most critical process parameters identified and optimized by QFD-Taguchi based hybrid approach, such as the injection pressure, the molten metal temperature, the plunger velocity (first and second stage) and the die temperature were explored in the experimental work. The results show that injection pressure is the most significant factor among the selected parameters. The contribution of the injection pressure to the variation of mean casting density is around 61.483%. Confidence interval (CI) has also been estimated as 0.000718 for 95% consistency level to validate the predicted range of optimum casting density of aforesaid alloy.

Key words: high pressure die casting; A380 alloy; QFD technique; Taguchi method; casting density