Research On Drawing Forming Of Engine Oil Filter Shell Of Automobile

Sheet forming is widely applied to many fields in national economy such as auto, machine, electron, aviation, national defence etc. It has many advantages such as high mechanization, large production, high surface precision and quality, forming complicated shapes, consuming less energy and resources etc. Deep drawing is one of most difficult methods in sheet forming. The force loaded is complicated in deep drawing, as viewed of mechanics, deep drawing belongs to very complicated triplicate nonlinear questions about geometry, physics, boundary conditions and non-continuous about boundary conditions, at the same time, it is limited by forming limitation of the materials, so it is very difficult to assure high quality, high production, consuming less energy and resources and to get high economic benefits. Just because deep drawing has so many difficulties and questions that research on it becomes very exigent in present. In addition, research on some shape production in deep drawing can not only guide the forming others shapes production in deep drawing, but guide others forming process.With the development of computer technology, numerical simulation is becoming perfect. The application of numerical simulation to forming sheet become more and more widely. In present, the technology has applied to optimize mould design and foresee forming defects etc. It is widely applied to education, science research and production fields. Numerical simulation is the most powerful tool by which to analyze nonlinear question, so the theme uses ETA-DYNAFORM as the tool, researches the deep drawing process of engine oil filter shell by numerical simulation.The mould design of sheet forming is an important condition that influences sheet forming ability. It will influence production quality and even influence that the forming can be completed or not. For example, abnormalmould round corners and gaps or manufacture and precision would increase the friction between mould and sheet or make stress centre on some part so that the production come into being defect. Abnormal heat treatment process would make the mould material soft, that would bring up"cold sweat"phenomena, in the end the mould would be damaged. From above, we must pay attention to the mould design and manufacture.The reason to select engine oil filter shell as the object is as following. At fist, it is the typical deep drawing part. The second, engine oil filter assure the gas engine normal running and its demands is very large. In the conventional process, the working procedure is excessive, production is lower, energy and resource are consumed largely, and these are its disadvantages. So research on it can save much energy and resources and acquire large economic and social benefits.The mainly researching content and results is as following:1, According to the continuous mechanics theory, the theme discusses the basic theory of numerical simulation. Abstracting the sheet forming question as a border value question of an differential equation, and compute the border value by finite element method or finite difference method, then acquire the displacement field, stress field, strain field and temperature field of the production and mould in the forming process, in order to foresee the defects in the forming process.2, The theme simulate respectively the forming process in different binder force, binder gap and friction coefficient conditions. The results indicate that with the binder force and binder gap increasing, the simulation results manifest:â‘ wrinkle in the forming areaâ‘¡high quality formingâ‘¢crack at the round corner. When the friction coefficient increase to a certain extent, the production produce cracks in the round corner. According to the change of the simulation results, the theme optimizes the process parameters such as binder force, binder gap and friction coefficient, in the end an ideal simulation result is acquired.3, Mould design is a key step in plastic forming, it influence the quality of plastic forming directly. It needs not only better specialty knowledge, but abundant design experience. According to parameters optimized and with the Professor Yu Ming's aborative help, all mould parts and others parts that is needed in the experiment are designed very well.4, Mould manufacture and process debugging is the key to acquire eligible production, too. Excellent mould design without excellent mould manufacture process and equipments can not produce eligible production. Process debuggingis an important step to acquire real and ideal process parameters and produce eligible productions, but it needs abundant debugging experience. With the Professor Yu Ming's help, the theme complete the mould manufacture and process debugging smoothly. The real and simulation result demonstrates each other, the result is very ideal.5, The limit drawing coefficient of each material indicates its limit drawing extent. When the limit drawing coefficient is selected, the forming is the most difficult. The theme successfully accomplishes the numerical simulation of one step forming of drawing and reverse drawing by finite element analysis software, and analyzes the simulation results through FLD picture, the picture proves that the new process is feasible in theory.6, The theme acquires some experiences through numerical simulation and process experiment as following:In present, some numerical simulation software have been mature very much, they can reflect relatively exactly and visual the forming condition of real material in the whole load. For example, wrinkle, crack etc. defects and the sheet thickness, stress and strain's distribution all can be shown visual. So it can availably guide process parameters establishment and optimization in deep drawing. Compared with conventional trying mould method, numerical simulation has many advantages such as less cost, simple operation, less time spent and visualization. Numerical simulation has some disadvantages, too. Software corporations are optimizing math model, but many computing condition have been idealized, so the simulation results can not indicate the real load and forming condition and have some warps sometimes. So combine the numerical simulation and experiment, the two methods revised each other, not only accelerates the course of process optimization and shortens the time of process optimization, but improve the simulation accuracy.Combining drawing and reverse drawing, the theme accomplishes deep drawing forming of engine oil filter shell in one step. Compared with conventional process, the new process improve accuracy and production of product, save large resource and energy, acquire large economic benefits, in addition, the new process reduce draining of waste water and oil, has some effects on protecting circumstances, so it acquire some social benefits.