Optimization of die casting conditions for wear properties of alloy AZ91D components using the Taguchi method and design of experiments analysis

This investigation applied the Taguchi method and designs of experiments (DOE) approach to optimize parameters for magnesium alloy AZ91D. Tribological properties of wear mass loss and friction coefficients were studied. Planning of experiments was based on a Taguchi orthogonal array table, and applied signal-to-noise ratios to determine an optimal setting. Furthermore, as the analysis of variance (ANOVA) was adapted to identify the most influential factors, the fusion slurry pressure was found to be the most significant factor. By applying regression analysis, a mathematical predictive model of the wear mass loss was developed in terms of the die casting process parameters. Additional runs were conducted in order to validate the optimal setting and compare the performance of the Taguchi method and the DOE approach. In this study, the wear mechanisms of adhesive and delamination for the AZ91D were found through wear tests. A specimen with a low wear mass loss has shown a low friction coefficient as well as small exfoliates and fractures.

[1]  Vinod Yadava,et al.  Experimental study and parameter design of electro-discharge diamond grinding , 2008 .

[2]  Alakesh Manna,et al.  Investigation for optimal parametric combination for achieving better surface finish during turning of Al/SiC-MMC , 2004 .

[3]  Yung-Kuang Yang,et al.  Experimental analysis and optimization of a photo resist coating process for photolithography in wafer fabrication , 2006, Microelectron. J..

[4]  Jun-Yen Uan,et al.  Surface compositional inhomogeneity and subsurface microstructures in a thin-walled AZ91D plate formed by hot-chamber die casting , 2005 .

[5]  Amir Arnon,et al.  The correlation between wall thickness and properties of HPDC magnesium alloys , 2007 .

[6]  I. Puertas,et al.  A Study of Optimization of Machining Parameters for Electrical Discharge Machining of Boron Carbide , 2004 .

[7]  Zhe Zhang,et al.  Optimizing surface finish in a turning operation using the Taguchi parameter design method , 2006 .

[8]  Ming-Hsien Caleb Li,et al.  Optimal parameter design for chip-on-film technology using the Taguchi method , 2005 .

[9]  Burak Birgören,et al.  Design optimization of cutting parameters when turning hardened AISI 4140 steel (63 HRC) with Al2O3 + TiCN mixed ceramic tool , 2007 .

[10]  Lieh-Dai Yang,et al.  Study of magnetic abrasive finishing in free-form surface operations using the Taguchi method , 2007 .

[11]  H Friedrich,et al.  Research for a new age of magnesium in the automotive industry , 2001 .

[12]  F. H. Froes.  Cost Effective Synthesis, Processing and Applications of Light-Weight Metallic Materials , 2003 .

[13]  Zhongrong Zhou,et al.  Fretting wear behavior of AZ91D and AM60B magnesium alloys , 2006 .

[14]  Fugee Tsung,et al.  A DMAIC approach to printed circuit board quality improvement , 2004 .

[15]  K. Palanikumar,et al.  Application of Taguchi and response surface methodologies for surface roughness in machining glass fiber reinforced plastics by PCD tooling , 2008 .

[16]  Yung-Kuang Yang,et al.  Optimization of Injection-Molding Process of Short Glass Fiber and Polytetrafluoroethylene Reinforced Polycarbonate Composites via Design of Experiments Method: A Case Study , 2006 .

[17]  Douglas C. Montgomery,et al.  Response Surface Methodology: Process and Product Optimization Using Designed Experiments , 1995 .

[18]  Syed H. Masood,et al.  Investigation of wear properties of magnesium and aluminum alloys for automotive applications , 2004 .

[19]  Yung-Kuang Yang,et al.  Optimization of a photo resists coating process for photolithography in wafer manufacturing via design of experiments method , 2006 .

[20]  Hasan Sofuoglu,et al.  A technical note on the role of process parameters in predicting flow behavior of plasticine using design of experiment , 2006 .

[21]  B. Mordike,et al.  Magnesium: Properties — applications — potential , 2001 .

[22]  Seh Chun Lim,et al.  Wear behaviour of SiCp-reinforced magnesium matrix composites , 2003 .

[23]  Chris Suman,et al.  The Effects of Direct Aging on Mechanical Properties and Corrosion Resistance of Diecast Magnesium Alloys AZ91D and AM60B , 1990 .

[24]  N. Tosun,et al.  Optimisation for hot turning operations with multiple performance characteristics , 2004 .

[25]  Peter J. Blau,et al.  Sliding friction and wear of magnesium alloy AZ91D produced by two different methods , 2000 .

[26]  T. R. Bement,et al.  Taguchi techniques for quality engineering , 1995 .