A Systematic Approach to Model and Optimize Qualities of Castings Produced by Squeeze Casting Process

The present study attempts to promote the quality of squeeze casting components by a two-stage study which includes experimental research of virtual casting based on response surface method (RSM) and experimental research of actual production casting. In the first stage, the critical parameters determined by the numerical model of casting procedure indicate that the qualities of castings, including casting solidification time, secondary dendrite spacing and porosity, are highly affected by the die temperature, pouring temperature and filling velocity. The input-output relationship developed, based on Box-Behnken experimental design (BBD), is found to be statistically adequate and yielded better prediction accuracy. NSGA-II algorithm performs multi-directional search in multi-dimensional space simultaneously combining with the data optimization software ISIGHT. In the second stage, the trial production test was carried out on the squeeze casting machine to verify the optimal parameters. X-ray inspection, metallographic structure testing and mechanics performance testing show that the casting has no casting defects and has good mechanical properties.