Investigating the Optimum Model Parameters for Casting Process of A356 Alloy: A Cross-validation Using Response Surface
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RESEARCH ARTICLE-MECHANICAL ENGINEERING
Investigating the Optimum Model Parameters for Casting Process of A356 Alloy: A Cross-validation Using Response Surface Method and Particle Swarm Optimization 1 Abdullah Tahir Sensoy ¸
· Murat Çolak2 · Irfan Kaymaz3 · Derya Dispinar4
Received: 11 April 2020 / Accepted: 29 August 2020 © King Fahd University of Petroleum & Minerals 2020
Abstract This study aimed to determine the optimal casting parameters for the maximum fluidity of A356 alloy. Gravity die cast method was used. For this purpose, central composite design (CCD) was performed. The input parameters and their limits for the trial design were selected as pre-heating temperature (100–400 °C), casting temperature (680–760 °C), and crosssectional thickness (1–10 mm). Using the CCD-based simulation results of the feed distance, a highly correlated full-quadratic regression equation was obtained with the highest R2 (0.99), which then was used as the objective function for the particle swarm optimization (PSO) process. The highest value of the response parameter, flow distance, reached up to 491.19 mm when the input parameters were selected as 400 °C, 760 °C and 10 mm, respectively. The sensitivity analysis has shown that the most effective parameter on the fluidity is the cross-sectional thickness. The response surface method (RSM)-based optimization results have been also validated using the PSO method. Although the higher temperatures have been found to result in better fluidity, there may be some drawbacks to working at higher temperatures such as energy cost and mould life. To determine the optimum input parameters, the RSM model suggested in this study can be modified for any type of casting process. Moreover, especially for a complex-shaped part, the manufacturer can be advised regarding operating conditions such as pre-heating and casting temperatures. Keywords Central composite design (CCD) · Response surface method (RSM) · Particle swarm optimization · Fluidity · Casting parameters
1 Introduction Casting can be defined as a manufacturing method by melting metals or alloys and pouring the liquid into a mould cavity and letting it to solidify to produce the part. This method is used to produce complex-shaped parts from any material that can be melted [1]. The parts manufactured by this method can vary in size from a few millimetres to several meters, and their weight can range from a few grams to sev-
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Abdullah Tahir Sensoy ¸ [email protected]
1
Engineering Faculty, Samsun University, Samsun, Turkey
2
Engineering Faculty, Bayburt University, Bayburt, Turkey
3
Engineering Faculty, Erzurum Technical University, Erzurum, Turkey
4
Chemical and Metallurgical Engineering Faculty, Istanbul Technical University, Istanbul, Turkey
eral tonnes. In particular, aluminium and its alloys have been commonly used as casting materials due to their excellent mechanical properties with regard to their lightweight. Furthermore, aluminium alloys have incomparable advantages for the industry due to their high co
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