Prakash Easwaran

• Nonwoven materials are used as filter media which are the key component of automotive filters such as air filters, oil filters, and fuel filters. Today, the advanced engine technologies require innovative filter media with higher performances. A virtual microstructure of the nonwoven filter medium, which has similar filter properties as the existing material, can be used to design new filter media from existing media. Nonwoven materials considered in this thesis prominently feature non-overlapping fibers, curved fibers, fibers with circular cross section, fibers of apparently infinite length, and fiber bundles. To this end, as part of this thesis, we extend the Altendorf-Jeulin individual fiber model to incorporate all the above mentioned features. The resulting novel stochastic 3D fiber model can generate geometries with good visual resemblance of real filter media. Furthermore, pressure drop, which is one of the important physical properties of the filter, simulated numerically on the computed tomography (CT) data of the real nonwoven material agrees well (with a relative error of 8%) with the pressure drop simulated in the generated microstructure realizations from our model. Generally, filter properties for the CT data and generated microstructure realizations are computed using numerical simulations. Since numerical simulations require extensive system memory and computation time, it is important to find the representative domain size of the generated microstructure for a required filter property. As part of this thesis, simulation and a statistical approach are used to estimate the representative domain size of our microstructure model. Precisely, the representative domain size with respect to the packing density, the pore size distribution, and the pressure drop are considered. It turns out that the statistical approach can be used to estimate the representative domain size for the given property more precisely and using less generated microstructures than the purely simulation based approach. Among the various properties of fibrous filter media, fiber thickness and orientation are important characteristics which should be considered in design and quality assurance of filter media. Automatic analysis of images from scanning electron microscopy (SEM) is a suitable tool in that context. Yet, the accuracy of such image analysis tools cannot be judged based on images of real filter media since their true fiber thickness and orientation can never be known accurately. A solution is to employ synthetically generated models for evaluation. By combining our 3D fiber system model with simulation of the SEM imaging process, quantitative evaluation of the fiber thickness and orientation measurements becomes feasible. We evaluate the state-of-the-art automatic thickness and orientation estimation method that way.