Study of High-Speed Microhole Drilling by Combined Process using Laser and EDM-Apply for fuel injection nozzle-

H. Morita, Tetsuji Yamaguchi, N. Mohri
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Abstract

In the automobile industry, increasing the demands for better environment protection and resource conservation entails for lowering both fuel cost and exhaust emission. This is because combustor efficiency is markedly influenced by grain size, spray pattern, and the injection volume of fuel atomization. Therefore, to increase combustor efficiency it is effective to improve the size, pattern, and accuracy of nozzle holes. In mass production, conventional processing methods for nozzle holes include stamping and drilling. Noncontact processes such as electric discharge machining (EDM) has the advantages of smaller size, better pattern flexibility and better accuracy, however, they are not suitable for mass production. In this study, we introduced a new EDM method with both good accuracy and good productivity that are suitable for the finish machining of microholes having a diameter less than 0.2 mm. We found that for finish boring by EDM, the smaller the depth of cut, the lower the processing efficiency. Thus, to solve this problem, we suggested a new method that entails overlaying high frequency vibration to the electrode, and verified the effectiveness of the method by experiments. We verified the effective use of a high-frequency electrode feeding device together with the direct drive method for improving the processing efficiency. The finish EDM developed method is now in practical use in the mass production of fuel injection nozzle holes, which start as preholes made using a YAG laser.
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激光与电火花复合高速微孔钻削研究——适用于喷油器
在汽车工业中,对环境保护和资源节约的要求越来越高,需要降低燃料成本和废气排放。这是因为燃烧室的效率受到颗粒尺寸、喷射模式和燃油雾化喷射量的显著影响。因此,改善喷嘴孔的尺寸、形状和精度是提高燃烧室效率的有效措施。在批量生产中,喷管孔的常规加工方法包括冲压和钻孔。电火花加工(EDM)等非接触加工具有尺寸小、图案柔性好、精度高等优点,但不适合大批量生产。在这项研究中,我们介绍了一种新的电火花加工方法,它具有良好的精度和良好的生产率,适用于直径小于0.2 mm的微孔的精加工。研究发现,对于电火花精镗,切削深度越小,加工效率越低。因此,为了解决这一问题,我们提出了在电极上叠加高频振动的新方法,并通过实验验证了该方法的有效性。我们验证了高频电极送料装置与直接驱动方法的有效使用,以提高加工效率。精加工电火花加工开发的方法目前已实际应用于喷油器孔的批量生产,这些孔最初是使用YAG激光制成的预孔。
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