Excerpt from the August 2018 article from the International Journal of Engineering & Technology by P. Nagasankar, et.al.
The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defects found through why-why analysis technique. Process capability of current high pressure die cast manufacturing is checked. The current problem of blowhole defects are solved by making an improvement in design of the die inserts. In-gate directions are changed to obtain modified improved flow patterns. Using magma flow simulation software, existing and modified design is compared. It is found that modified design shows superior results, and using this, the defect of blowholes is minimized satisfactory.