INTERNAL CONIC SURFACE GRINDING PROCESS ANALYSIS IN EURO5 DIESEL NOZZLES

摘要

A more efficient use of natural resources leads industry to increase the efficiency of manufactured products. Transportation Diesel vehicles are included in this scenario. In Diesel engines, one important component of the injection system is the nozzle injector. A recent legislation in Brazil introduced EURO5 emission limits. These new parameters had impact on nozzle design with tolerances being reduced, in special on nozzle body seat area, changing the functional parameter of nozzle opening pressure. In this scenario, the grinded conic surface impacts on this functional parameter, thus on the Diesel engine performance. This study aims to relate the grinding process, surface generated in the process and the Diesel nozzle opening pressure variation; the goal is to reduce waste in manufacturing, generating less surface roughness dispersion in grinding process. Planned process tests were performed according to Taguchi methods and it was determined signal-noise ratio to surface roughness parameters. The seat surface will be analyzed using 2D and 3D roughness measuring equipments. Study results includes grinding process parameters optimization for smaller surface roughness, roughness relation to nozzle opening pressure and scrap cost reduction in the manufacturing process. These points will be achieved through determination of surface roughness parameters that could detect surface quality problems after grinding process which means knowing the problem without the need of functional measuring at the end of the process chain.