Conical surfaces can be applied in the valves of liquid seal. In the fuel injection unit of a diesel engine, an outer conical surface at the tip of a slender needle works with an inner conical surface as injector-body seat to realize the switching and sealing of a fuel passage. So far, the conical surfaces are usually machined by mechanical grinding. The small grinding wheels < ϕ3 mm and its rotation speed > 100,000 RPM have to be utilized for achieving enough circumferential speed. The inner conical surface is located in a small and deep bore, so the insufficient stiffness of the grinding tool is easy to cause machining errors. In this research, the process of wire electro discharge grinding (WEDG) by using a line-segment wire discharge (called line-segment WEDG in this paper) was explored for machining such conical surfaces. The emphasis was focused on the effect of wire alignment error on the accuracy of the conical surfaces. By the line-segment WEDG, an outer conical surface, or a conical tool electrode, can be machined directly and whereby an inner conical surface can be machined by die-sinking electro discharge machining (EDM). Machining experiments achieved some promising results including the outer conical surfaces with a total height of waviness profile Wt < 2.5 μm and surface roughness of R a0.4μm, the inner conical surfaces with Wt < 1.5 μm and R a0.2 μm, and all cone-angle errors are less than 0.1∘.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Nov 8, 2017
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