3D-Printed Fuel Injection Thread Geometry for Surface Roughness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The 3D printer technology of the lamination type faces challenges in surface roughness and manufacturing cost due to the formation of uneven overhang shapes in male screw portions, particularly when the overhang angle exceeds 45 degrees, making it impractical for fuel injection elements, which necessitates separate assembly and increased manufacturing processes.
Innovation Solution
A three-dimensional additive manufactured product with a male screw portion having a first flank angle of at least 45 degrees, allowing integral molding with the body portion while maintaining surface roughness within practical limits, and optionally a second flank angle of zero degrees to minimize length, ensuring durability and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the male screw portion is formed integrally with the body portion using 3D printer technology, then manufacturing cost is reduced and production efficiency is improved, but surface roughness increases when the overhang angle is not less than 45 degrees
Solution Approach 1:
The invention changes the geometric parameter of the male screw portion by setting the overhang angle to less than 45 degrees. This parameter modification allows the screw portion to be formed integrally with the body portion using 3D printing technology while maintaining acceptable surface roughness, thus resolving the contradiction between manufacturing efficiency and surface quality
2Manufacturing precision
If the overhang angle of the male screw portion is decreased to less than 45 degrees, then surface roughness is reduced to practical levels, but the length of the male screw portion increases to ensure sufficient number of pitches
Solution Approach 1:
The invention optimizes the overhang angle parameter to be less than 45 degrees, which balances two competing requirements: maintaining surface roughness at practical levels while minimizing the increase in screw portion length. This parameter optimization allows integral formation of the screw portion without excessive lengthening
3Manufacturing precision
If the male screw portion is formed as a separate member and mounted to the body portion, then surface roughness is controlled, but the number of manufacturing processes increases and cost reduction effect is insufficient
Solution Approach 1:
The invention merges the male screw portion and the body portion into a single integrally formed component using 3D printing technology. By optimizing the overhang angle to less than 45 degrees, the screw portion can be printed directly without separate manufacturing and assembly processes, thus reducing process complexity while maintaining acceptable surface quality
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 configuration enables the integral molding of the male screw portion with the body portion, reducing manufacturing processes and costs, while maintaining surface roughness and durability, thus achieving a cost-effective three-dimensional additive manufactured product.
Implementation Method 1
the three-dimensional additive manufactured product is molded by forming a sintered layer by irradiating a powder bed formed with the powder materials with a beam
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The three-dimensional additively-formed product comprises: a body section; and a male threaded part integrally formed with the surface of the body section in a projecting manner. The male threaded part has a trailing flank forming a first flank angle with respect to the plane perpendicular to the axial line. The first flank angle is 45 degrees or greater.