The present research work is focussed to develop an intelligent system to establish the input-output relationship utilizing forward and reverse mappings of artificial neural networks. Forward mapping aims at predicting the density and secondary dendrite arm spacing (SDAS) from the known set of squeeze cast process parameters such as time delay, pressure duration, squeezes pressure, pouring temperature, and die temperature. An attempt is also made to meet the industrial requirements of developing the reverse model to predict the recommended squeeze cast parameters for the desired density and SDAS. Two different neural network based approaches have been proposed to carry out the said task, namely, back propagation neural network (BPNN) and genetic algorithm neural network (GA-NN). The batch mode of training is employed for both supervised learning networks and requires huge training data. The requirement of huge training data is generated artificially at random using regression equation derived through real experiments carried out earlier by the same authors. The performances of BPNN and GA-NN models are compared among themselves with those of regression for ten test cases. The results show that both models are capable of making better predictions and the models can be effectively used in shop floor in selection of most influential parameters for the desired outputs. 1. Introduction The mechanical properties in castings majorly depend on the density and secondary dendrite arm spacing. The density and secondary dendrite structure are significantly influenced by the operating conditions of the squeeze cast process variables. In majority of the foundries, industrialists are trying to establish the input-output relationship through the use of process simulation software like procast and magmasoft. The significant effect of process parameters on the temperature difference in the squeeze casting process was studied using artificial neural networks and procast simulation software [1]. Later on, authors extended their research efforts to study the solidification time (which has direct influence on the formation of secondary dendrites) with various squeeze casting conditions by using the combinations of artificial neural network and procast simulation software [2]. However, simulation software considered being often inefficient, where large number of process variables need to be examined and large number of repetitive analysis are required in the selection of most influential process variables. This will considerably increase the execution time and computational
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