An experimental investigation of abrasive suspension flow machining of injector nozzle based on orthogonal test design
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ORIGINAL ARTICLE
An experimental investigation of abrasive suspension flow machining of injector nozzle based on orthogonal test design Minghui Fang 1 & Tao Yu 1,2 & Fengfeng (Jeff) Xi 3 Received: 24 April 2020 / Accepted: 9 August 2020 / Published online: 19 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The application of abrasive suspension flow machining (ASFM) to grind a diesel engine injector nozzle is discussed in this paper. The purpose is to remove the sharp corners of the spray holes and improve the fuel flow through the injector nozzle. The proposed method adopts one-way flow to grind the spray holes for high-efficiency production. Compared with traditional reciprocating flow grinding methods using abrasive pastes, the viscosity of slurry and abrasive concentration of ASFM are lower, better for more smooth flow. To achieve a good grinding performance, it is important to determine proper viscosity and concentration. For this purpose, a design of experiments (DoE) method is adopted. In this paper, an orthogonal test method is combined with a nonlinear regression method to optimize the process parameters. Through a range analysis on experiment results, the optimal process conditions in terms of the grinding efficiency and the grinding quality are determined. Experiment verifications show that the optimized process parameters can significantly improve the ASFM grinding efficiency and grinding quality. Keywords Abrasive suspension flow machining . Injector nozzle . Orthogonal test design . Grinding performance
1 Introduction Abrasive suspension flow machining (ASFM) is a new grinding technology that came forth in recent years [1]. This method was originally developed for aerospace applications and later introduced to diesel engine applications, including micro-hole finishing such as injector nozzles and bonnets. Abrasive suspension slurry is a type of non-Newtonian fluid, made up of viscous lubricating oil, polymer agent, abrasive, and additives. The polymer agent is used to suspend the abrasive particles uniformly in the viscous slurry that acts as a carrier medium to bond abrasive particles together to form a loosely bonded grinding tool. The suspended abrasive particles (grinding tool) are extruded to pass through a surface to grind off roughness. The salient advantage of ASFM lies in
* Minghui Fang [email protected] 1
School of Mechatronic Engineering and Automation, Shanghai University, Shanghai, China
2
Shanghai Polytechnic University, Shanghai, China
3
Department of Aerospace Engineering, Ryerson University, Toronto, Canada
the uniformity of the polished surface, especially when a high precision is required. There are a couple of important findings pertaining to injector nozzles. The first is that a good grinding quality would result in roundness of the spray holes and an even flow efficiency among the injector nozzles. The second is that removal of the sharp corners and chamfering the edges of the spray holes would greatly improve the thermal and mechanic
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