Paper Title
Experimental Investigation and Defect Analysis of High Pressure Die Casting For Main Housing Load Cell

Die casting is often encountered with many problems, few of such problems are blowholes, improper filling, scratch marks, weld lines, cracks, cold shut, porosity, blisters, ejector pin marks, etc. usually these defects are caused due to improper design of dies, or due to incorrect parameters such as injection pressure, cycle time, cooling circuits and other such parameters. When these problems arise after manufacturing of die and component production, which will be loss to the company as there will be wastage of money, time and also problem of customer dissatisfaction. In order to overcome these problems, in this thesis a set of analysis is carried on main housing load cell component to ensure that design and other parameters are safe and efficient. The analysis is performed to predict the molten metal behavior after injection in to the die. At first the component is modeled in 3D modeling software Pro/Engineer. The spreader, runner, gate and overflows are designed for the component. Analysis software Ansys Fluent is used to analyze the behavior of molten metal at different stages of time by observing the results of temperature variations, pressure variations and liquid fractions. The input parameters are molten metal temperature, die temperature and velocity of flow. Optimization technique Taguchi is applied to determine the better parameters. After optimizing the parameters, experimental work is done and the component is successfully produced.