The improvement in deep drawing process for producing air filter by using finite element method

Abstract

This research had improved the production of filter in deep drawing process. By using finite element method,
FEM, in the analysis, optimum products design could be achieved. The material SPCE with thickness of 0.6 mm.
had been used to produce the cup with diameter 102 mm. and height 145 mm. High quantities of rejected
products were discovered with crack defects, which caused the production to be less competitive with other
companies. Therefore, the improvement of production design had been proposed to design the suitable processes.
The production improvement processes involved 5 processes which design drawing ratio of β=1.5, 1.5, 1.1, 1.8,
and 1.07 respectively.
In the analysis, the material properties had assumed to behave as elastic-plastic according to power law of
Ludwik with K = 320 N/mm2 and n = 0.085. According to Hill’s the anisotropy of sheet metal were r0=1.87 r45= 1.30
and r90= 2.14. From the results of FEM, the forming ability of high cup cannot be drawn within a single process.
The part size should be reduced with suitable drawing ratio which decreased the lease sheet thickness. The
simulation results shown the strain on parts were within the forming limit diagram, which the lowest part thickness
was 0.53 mm without damage occurred. Thus occurred stress and strain at fracture were comparable to the
Gurson Model, GTN.
From the analysis of deep drawing process for producing filter, the production cost had been reduced such as
die machining, die trial and error, materials wasted, labor cost, and machines power. The higher production
quality and production efficiency can be observed, which will increase the company ability to compete in the
future market. This investment in the modeling technology reflected in reduction of the manufacturing cost and
increase the company benefits