Fuel Injector Pintle Forming to Reduce Material Waste

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Solution Overview

Problem

Current methods for producing pintles for fuel injectors result in significant material waste through machining and can lead to weak connections and reduced service life when producing separate parts.

Innovation Solution

A method involving metal forming operations on a steel alloy workpiece to change the radial dimensions, creating the pintle perch and shaft without removing material, followed by heat treatment and optional machining for fine adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If machining is used to produce the pintle from a cylindrical workpiece, then the desired external shape and surface quality are achieved, but more than 70% of the material is removed as scrap

Engineering Contradiction:

Improveexternal shape and surface qualityVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The invention changes the manufacturing parameters from subtractive machining to additive forming. The workpiece is formed by applying pressure through a die to plastically deform the material into the desired shape, preserving essentially all material while achieving the required external geometry and surface quality without the need for extensive machining removal.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical machining system (cutting tools, lathes, grinders) with a forming system that uses controlled plastic deformation. Instead of removing material through mechanical cutting, the process uses a die to shape the material, substituting a different mechanical mechanism that preserves material integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of substance

If the pintle is produced by joining separate perch and shaft pieces, then material waste is reduced, but the connection becomes a weak point reducing service life

Engineering Contradiction:

Improvematerial wasteVSAvoidservice life

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The invention merges the perch and shaft into a single integrated component formed from one workpiece. The forming process creates the complete pintle structure with the perch and shaft as continuous, unified material, eliminating the need for joining operations and ensuring structural integrity throughout the entire component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

While the final product is unified, the forming process utilizes segmented tooling and staged deformation to create the different sections (perch and shaft) through controlled plastic flow. The die structure allows different regions of the workpiece to be formed simultaneously or sequentially while maintaining material continuity, achieving both efficiency and structural integrity.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If conventional machining processes are used, then the pintle can be manufactured with standard equipment, but the process is time-consuming and energy-intensive

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention performs the shaping action during the forming process itself rather than requiring subsequent machining operations. The die is designed to create the final external geometry directly during forming, eliminating the need for preliminary or subsequent cutting, turning, or grinding operations that would extend production time and energy consumption.

Inventive Principle:

Principle #10Preliminary action

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 method reduces material waste, minimizes tool wear, and enhances mechanical stability by aligning fibers parallel to the surface, thereby reducing the risk of fractures and improving the overall quality and service life of the pintle.

Implementation Method 1

performing at least one metal forming operation on a workpiece to change the radial dimension of at least a portion of the workpiece

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

followed by heat treatment and optional machining for fine adjustments

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS20250027471A1Method for producing a pintle for a fuel injector

Publication Date: 2025.01.23 PHINIA DELPHI LUXEMBOURG SARL

AI summary

A method for producing a pintle for a fuel injector, which pintle extends in an axial direction and has a pintle perch with a perch radius as a maximum radial dimension and a pintle shaft with a shaft radius as a maximum radial dimension smaller than the perch radius.The method comprises:providing a metal workpiece; andperforming at least one metal forming operation on the workpiece to change the radial dimension of at least a portion of the workpiece.The at least one forming operation comprises axially compressing a portion of the workpiece, whereby the portion radially expands, wherein expanding the portion is used for creating the pintle perch.