Investigation & Optimization of the Forming Parameters Causing Thinning of an Oil Filter Cap of an Automobile Engine

Now a days manufacturing of uniform thick component is done with the help of forming methodology, forming methodology involves many challenges like-punch diameter, die radius, clearance, lubrication, blank holding force and its trajectories etc. So designing the tools for component needs a lot of prototype test procedure. To reduce number of prototype test steps, the process can be done by using finite element packages. Even the CAE gives an approximation towards the solution. The dissertation work is relevant in the context of developing a cost effective component with a lower development time through the phase of Design, Development, Trials and Testing, lot production & Regular supply. In this dissertation work, the significance of three important deep drawing process parameters namely blank Holding force, die arc radius and punch nose radius on the deep drawing characteristics was determined. Existence of thickness variation in the formed component may cause stress concentration and may lead to acceleration of damage. The CAE method is a powerful tool to predict material thinning deformations before prototypes are made. In this dissertation work, the combination of finite element method and Taguchi design of experiments and has been applied to analyze the influencing Design parameters on Thinning in automotive deep draw component.