Development and verification of cold forging filter housing production design with finite element model support

High-pressure hydraulic filter housings are critical components that enable filters to operate under pressure, performing direct oil filtration functions in challenging environments such as mining, maritime, automotive, and aerospace. These filter housings are used in subsystems of high importance, such as aircraft engines and landing gear, and may sustain damage due to durability issues before reaching their expected service life. In this context, high-pressure hydraulic filter housings are considered critical components from a safety perspective. This study aims to achieve the physical and mechanical properties of filter housings produced through cold forging, tailored to meet the requirements of their specific application fields. Additionally, it is intended to contribute to the national economy by reducing raw material costs through existing manufacturing methods and integrating high-value-added products into the market. Using Finite Element Method (FEM)-supported simulation software, the cold forging process is analyzed, and the necessary parameters for the production of high-strength products are determined. During the cold forming process of the workpiece, the principle of volume constancy is taken into account, and the geometry of the raw material, suitable press properties, operational die designs, and die characteristics are determined. Sequence designs have been completed and prototype production has been carried out with FEM-assisted analyses. A digital twin of the cold forging operations has been created, allowing for comparisons between simulation and real data. Deformation force, material flow, contact pressure, stress, strain, and dimensional changes in the final product have been analyzed in detail. Destructive and non-destructive testing methods have been employed to examine the samples, and the targeted mechanical and physical properties have been evaluated. As a result, the filter housing design that meets the varying high-strength requirements according to the intended application has been optimized for service in hydraulic systems. By enhancing stress and strain rates, the physical and mechanical properties of the product have been improved.