Design of Plastic Frame for Primary Filter for a Manufacturing Industry

Chee, Wei Yau (2022) Design of Plastic Frame for Primary Filter for a Manufacturing Industry. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Primary filter, also known as a pre-air filter, is a filter used for separating contaminants from the air using. By using this primary filter, the main filter can be maintained in good condition. It longer the usage life of the main filter. This project aims to find a suitable solution for NIWOTA Premium Steel Craft Manufacture that is to redesign the primary filter with thermoplastic with the goal to reduce the manufacturing and assembly time and cost to improve productivity in original metal frame. In this project, research on the primary filter such as current primary filter on market, mechanical properties of various type of plastic, information of the filter media, guidelines of snap-fit design and injection moulding for plastics. The study of patents for similar product has been carried out in literature review to have a better undertanding in the design of plastic primary filter. The design input of the primary filter including Voice of Customer, product sample and its dimenions were provided. With the input parameter are given and used for static structural analysis onprimary filter. Solidwork is used to draw the conceptual design of the primary filter in this project. In this project, three conceptual design was proposed, and choose the best design. The final design of this project is the primary filter is design by using the concept of cantilever snap-joint with ABS plastic material. Engineering analysis was conducted through simulation and experimental testing by protoype. In simulation, 3D primary filter model was subjected to structural stress analysis, strain analysis, and Factor of Safety analysis by using Solidworks. The static analysis also compare the stength of metal rod with plastic rod. In the design of ABS primary filter, all the parts has a higher factor of safety than 2 to ensure primary filter will not break where loading and environmental conditions are not severe. For fatigue analysis, the Stress-Life (S-N) showed that the snap-fit of the primary filter can be assembly and dissassembly 3631 times without breaking. CFD simulation also conducted in this project in order to analyze the presssure drop of optimaized design compare to current design, which result in oprimzed primary filter has 7.54% higher pressure drop compare to original design since the plastic rod has bigger dimension. By using CES Edupack 2018, ABS primary filter require less 78% energy and produce less 85% of CO2 Footprint to produce a product compare to Aluminum Primary Filter. A prototype was fabricated for assembly testing, and the result is by using snap-fit it reduce 33.93% assembly time compared to original aluminum primary filter design