Abstract
Within the scope of Euro 7 emission norms, new types of injectors and engine parts are produced in order to reduce fuel consumption to minimum levels in diesel engine vehicles and accordingly to reduce emission rates. The complex geometry, high precision and high strength required by the nozzle design that will meet the requirements of the aforementioned norms have made the produc-tion of the required nozzles on existing production platforms difficult and the manufacturers have faced serious problems. Manufacturing companies needed the development of tooling systems suitable for the existing production platform rather than investing in the high-cost machine park. In this study, it is aimed to increase the tool life by choosing the most appropriate machining parameters for the surface quality obtained in the production of a single nozzle, which is de-signed and manufactured using six different tools, which will enable the use of existing machining platforms in the production of Euro 7 nozzles. The average surface roughness value on the nozzle surfaces was determined as Ra = 0.34 µm and it was observed that the desired surface quality was achieved. Performance tests have shown that the design and production activities are successful and that the developed tooling system can be used for the production of Euro 7 Nozzle from existing production platforms.
Highlights
It is known that new type injection nozzles are planned to be used in new-generation diesel engines
In order to verify the nozzle geometries and surface quality obtained in the drilling tests, the samples were cut using a wire electro erosion machine based on the hole axis (Fig. 5)
Average surface roughness measurements were made on the nozzle surfaces after cutting and Ra values were determined
Summary
It is known that new type injection nozzles are planned to be used in new-generation diesel engines. It has been determined that in particular to AISI 304 austenitic stainless steel, studies have been carried out to prevent tool wear encountered during machining, to increase hole quality, to determine optimum machining parameters and to compare them with existing tools These studies focused on the values that affect the hole quality such as surface roughness, burr height, and conic hole formation. They focused on machining parameters such as cutting speed, feed rate, rotation speed, and tool properties such as the drill tip angle and the tool material and type of coatings. It is aimed to increase the tool life by choosing the most suitable machining parameters for the surface quality of many nozzles produced using six different tools
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