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In this research work, thorough study has been conducted to decrease the porosity that arises during high pressure die casting. ANASYS (15.0), a computer aided engineering software has been used to reduce the porosity defect that arises during casting process. The reading, dimensions and specifications of the injection chamber have been taken from a die casting machining plant. The main objective is to reduce porosity from the end product which is a 100 watt LED light frame in this case. The changes in the pressure of molten metal flow has been observed inside the injection chamber which has been modeled using ANSYS fluent. And it has been found that when the pressure of molten metal flow is reduced, porosity also tends to get reduced or completely vanished. Nondestructive testing (NDT) is the process of inspecting, with the help of NDT testing we can find the inner defect of the casting and any other product like Porosity defect this defect. In this research work we find the minimum porosity with the help of NDT and we are using X-ray radiography testing. Radiography testing is the part of NDT so finally we have decreased the porosity.

Modeling and Analysis of Injection Chamber of HP Die Casting M/C