Austenitic Steel Fuel Manifold Deburring
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Solution Overview
Problem
Existing fuel manifold production methods for internal combustion engines face issues with residual stresses and reduced corrosion resistance due to chromium carbide formation, and require separate deburring and cleaning processes that increase costs and complexity.
Innovation Solution
The use of austenitic special steel for the fuel manifold, with mechanical deburring integrated into the machining process, allowing for higher pressure design, reduced material stress, and simplified production by eliminating the need for electrochemical deburring and additional strength-enhancing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrochemical deburring (ECM) is used to remove burrs, then deburring effectiveness is improved, but device complexity and manufacturing cost increase due to separate installation and cleaning processes
Solution Approach 1:
The patent combines the deburring function directly into the machining center by integrating a retraction deburrer, eliminating the need for separate ECM installation and cleaning processes. This merging of functions reduces device complexity while maintaining deburring effectiveness.
Solution Approach 2:
The machining center performs its own deburring operation through the integrated retraction deburrer, eliminating the need for separate dedicated deburring equipment and subsequent cleaning processes. The system serves its own deburring needs internally.
2Reliability
If conventional heat treatment is applied to redissolve chromium carbides, then corrosion resistance is improved, but production time increases due to prolonged treatment duration
Solution Approach 1:
The patent changes the material composition by using austenitic special steel with optimized chromium content and carbide-forming element ratios. This compositional parameter change prevents excessive chromium carbide formation, reducing or eliminating the need for prolonged heat treatment while maintaining corrosion resistance.
Solution Approach 2:
The patent performs preliminary action by optimizing the steel composition before manufacturing to prevent chromium carbide formation in the first place. This preventive approach eliminates the need for subsequent corrective heat treatment processes.
3Strength
If forging blanks are used for fuel manifold production, then mechanical strength is improved, but residual stresses from the forging process reduce corrosion resistance
Solution Approach 1:
The patent changes the material parameters by using austenitic special steel with specific alloy compositions that are less susceptible to carbide formation and residual stress effects. This material parameter change allows the forging process to produce both high strength and good corrosion resistance simultaneously.
4Productivity
If retraction deburring is integrated into the machining process, then productivity is improved, but machining complexity increases
Solution Approach 1:
The patent merges the deburring function into the existing machining center by integrating a retraction deburrer. This combination allows both machining and deburring to be performed in one setup, improving productivity without requiring completely separate complex systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances cyclic strength under pulsating pressure, reduces manufacturing costs, and improves machining characteristics, while avoiding material nonuniformity and short circuits associated with electrochemical deburring.
Implementation Method 1
The retraction deburrer (50) is brought into contact with the boring tool (200) in order to mechanically deburr the intersection region (40)
Implementation Method 2
a material state under compressive residual stress may be obtained which exhibits higher cyclic strengths, in particular under pulsating internal pressure stress
Data Source
AI summary
A component for an injection system for mixture-compressing, spark-ignition internal combustion engines, which is used to apportion a fluid under high pressure, in particular a high-pressure line or fluid manifold. The component includes a main body on which at least one hydraulic connection is provided, at least the main body having the connection being formed by single stage or multistage forging, an interior being formed on the main body by chip-removing machining after forging and a connection channel, which intersects with the interior in an intersection region, being formed at the connection by chip-removing machining after forging. The intersection region is deburred by mechanical deburring. An injection system and a method for producing such a component are also described.