Comparative Analysis and Evaluation of Fuel Injection Inspection 3d Printed Cover Part Design

Abstract

Automotive industry leaders face a dual challenge of cost management and ensuring optimal comfort, compelling them to continuously pursue innovation. Polymers have gained widespread application in various automotive components due to their lightweight nature and advantageous properties, including corrosion resistance, durability, design flexibility, toughness, resiliency, and high performance at a cost-effective rate.

This research aims to assess the most suitable polymer for the inspection cover part of a diesel fuel injector. The primary role of this component is to prevent diesel spillage from the pump housing during fuel supply to the injectors. Traditionally, the inspection cover part has been manufactured using aluminum through pressure die casting. However, the high cost and weight of aluminum, coupled with its mechanical and thermal properties exceeding the component requirements, necessitate exploration of alternative materials.

Material selection for the inspection cover part is performed employing CES software, aligning with the specific needs and limitations of the component. The chosen material undergoes numerical analysis for stress and strain using a commercial Finite Element Analysis (FEA) package. The component prototype is fabricated using the Fused Deposition Modeling (FDM) method, accompanied by a tensile specimen for evaluating mechanical properties. The results indicate that the selected polymer material is substitute for aluminum, offering potential advantages in terms of cost and weight.