Multi-objective optimization of process parameters during low-pressure die casting of AZ91D magnesium alloy wheel castings

• Main Authors: Chen Zhang, Yu Fu, Han Wang
• Format: Article
• Language: English
• Published: Foundry Journal Agency 2018-09-01
• Series: China Foundry
• Subjects: magnesium alloy; multi-objective optimization; process parameters; shrinkage porosity; secondary dendritic arm spacing
• Online Access: http://ff.foundryworld.com/uploadfile/2018092031930715.pdf

Multi-objective optimization has been increasingly applied in engineering where optimal decisions need to be made in the presence of trade-offs between two or more objectives. Minimizing the volume of shrinkage porosity, while reducing the secondary dendritic arm spacing of a wheel casting during low-pressure die casting (LPDC) process, was taken as an example of such problem. A commercial simulation software ProCASTTM was applied to simulate the fi lling and solidifi cation processes. Additionally, a program for integrating the optimization algorithm with numerical simulation was developed based on SiPESC. By setting pouring temperature and fi lling pressure as design variables, shrinkage porosity and secondary dendritic arm spacing as objective variables, the multi-objective optimization of minimum volume of shrinkage porosity and secondary dendritic arm spacing was achieved. The optimal combination of AZ91D wheel casting was: pouring temperature 689 °C and fi lling pressure 6.5 kPa. The predicted values decreased from 4.1% to 2.1% for shrinkage porosity, and 88.5 μm to 81.2 μm for the secondary dendritic arm spacing. The optimal results proved the feasibility of the developed program in multi-objective optimization.