Computer-Aided Process Development and Die Design for Manufacturing a Fuel Injector Nozzle

Higher strength and tighter dimensional accuracy is desired for the injector nozzles in order to attain high injection pressures for lower particulate and NOx emissions. Cold forming is an alternate method for making the injector nozzle which can provide these characteristics replacing the present machining operation. Experimental tests to study the material characteristics and two dimensional finite element simulation combined with knowledge-based system analysis were used to design a multi-stage sequential process to manufacture the injector nozzle. An interface program provides an efficient data exchange after process simulation for punch stress analysis.