Application of DOE (Design of Expert) in Parametric Optimizing of Al Alloy (6061T6) used in Automotive Wheel Hub

Abstract

Response surface methodology (RSM) is an effective and influential optimization tool, which is mostly applied for casting optimization. In the current work Aluminium, alloy wheel hub casting is taken into consideration using BOX-BEHNKEN design, three different levels of each parameter were considered. Solid modeling of casting and gating systems is done by CAD. Simulations of Aluminium Alloy (6061T6) casting were performed in PRO-cast. The simulation result shows that selected parameters significantly affect the quality of the casting. ANOVA is employed to examine the relationship between the factors. Input parameters namely flow rate, pouring temperature and runner size were taken to reduce the volume of shrinkage porosity. Experimental Design consists of 15 experimental trials and output data obtained from the simulation will be optimized through Minitab-18. The result indicates that selected independent variables significantly influence the response. ANOVA gives the optimized value of selected factors which reduces the porosity volume up to 30cm³.