In the previous article we looked at the second stage of the hydraulic filter design process, the design phase.
This month we will focus on the third stage of our five-stage design process: the simulation test.

Advanced simulations: Design optimisation before prototyping 

A key step in the design process at UFI Filters Hydraulics is a thorough analysis of the design using advanced simulations.

Once the detailed 3D model of the filter has been created, we carry out a double simulation:

• Finite Element Analysis (FEA): These analyses allow us to assess the mechanical resistance of the filter to various stresses, such as high pressures and vibrations, ensuring maximum robustness and durability.
• Fluid dynamic simulations (CFD): These simulations allow us to accurately study the fluid flow inside the filter and optimise the geometry to minimise pressure drop and maximise filtration efficiency.

These sophisticated simulations enable us to

• Optimise the design: We continually refine the design, identifying critical areas and making targeted improvements.
• Reduce costs: By limiting the need for physical prototypes, we accelerate time-to-market and reduce waste.
• Increase reliability: We virtually test the behaviour of the filter under different operating conditions, ensuring high performance and long life.

We also optimise the design process for three main reasons:

1. Flexibility: Simulations allow the designer to explore more possible scenarios, reducing uncertainty before creating the physical prototype.
2. Significant cost savings:

• In the design phase: thanks to preventive optimisation, it is often sufficient to create a single prototype, since critical issues are identified in advance.
• In the production phase: they allow better planning and provide a clearer view of potential problems.

3. Significant time savings:

• It is much easier to make changes to the virtual model than to rebuild a physical prototype.
• This allows the designer to proceed with greater confidence during the product validation phase, reducing the number of tests required if results do not meet initial specifications.

In this way, simulation becomes a fundamental element in the development of ever more efficient and reliable hydraulic filters.

Structural Simulations (FEA)

FEA simulations make it possible to analyse the internal stresses and forces to which the various filter components are subjected.
At UFI Filters Hydraulics, we use these simulations to

• Verify the compression forces of the gaskets: We evaluate the forces generated by the compression of the seals to ensure their proper functioning.
• Analyse reactions on threaded elements: We carry out a detailed analysis of the threaded elements, including extraction of the forces acting on them for subsequent accurate verification.
• Identifying maximum and minimum stress points: We evaluate stresses within the material to optimise thicknesses and perform targeted fatigue analysis of components.

Using these simulations, we can ensure the structural strength of the filter and optimise the geometry and thickness of the components, reducing production costs without compromising quality.
At this stage, the experience of the designer is crucial in interpreting the results and further refining the design.

Computational Fluid Dynamics (CFD) simulations

CFD simulations are used to analyse the behaviour of the fluid inside the filter, focusing on flow velocity and pressure drop.
The aim of the simulation is to minimise changes in flow velocity and direction within the filter in order to limit the resulting pressure jumps.
Although it is not always possible to eliminate these phenomena completely, efforts are made to achieve the best possible optimisation.

At UFI, CFD simulations are mainly used for complex geometries or for the development of completely new filters, where it is crucial to verify that the design allows for correct flow distribution and optimum efficiency.

A dedicated simulation department

Given the sensitivity of this phase, UFI Filters Hydraulics has created a dedicated structural and fluid dynamics simulation department, based in India and comprising a team of 10 experts.
These professionals work closely with the designers to ensure that each simulation is as accurate as possible, thus helping to define the final design of the filter before prototyping.

This approach enables UFI Filters Hydraulics to optimise projects from the earliest stages, ensuring high quality, competitive products.

Stay tuned to our blog to learn more about the next steps in our design process, from prototyping to final testing.