A Decision Support System (DSS) for the Prediction and Selection of Optimum Operational Parameters in Pressure Die-Casting Processes

A large number of material and process parameters affect both the part quality and the process performance in pressure die-casting (PDC) processes. The complex relations between most of these variables make PDC process optimisation a difficult issue which has been widely studied for many years. Although there are several analytical and numerical models to optimise certain process parameters, it is difficult to establish a specific operational configuration for PDC machines that ensures the joint optimisation of these variables. Therefore, in this study, some of these optimisation models have been implemented in a Decision Support System (DSS) that allows us to define an operational region that establishes a setup of machine parameters that ensures the manufacture of quality parts. By using this DSS, the user can set the values of the input variables related to the casting material, the die, or the casting machine. Then the corresponding calculations are made by the system and the results are expressed in terms of certain output variables such as the maximum filling time, maximum filling fraction, or the plunger velocity profile among others. The DSS allows the user to estimate the influence between input and output variables and find proper values for the input variables to achieve an optimum operational range. Consequently, improved process performance can be achieved taking into account productivity, part quality, and economic aspects.