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Deburring, Polishing and Surface Finishing - Extrude Hone Corporation®
Deburring, Polishing and Surface Finishing - Extrude Hone Corporation®
Related Links - AFM | MicroFlow AFM | ECM | Contract Services | Equipment | Diesel Power | Fuel Injectors
AFM Applications in Diesel
The introduction of the Extrude Hone Abrasive Flow Machining (AFM) process, specifically our MicroFlow™ AFM technology, forever changed the diesel fuel injection industry by providing a machining process that goes where no process had gone before — deep inside the workpiece. Today, AFM and MicroFlow AFM processing allow manufacturers to produce internal structures, controlled radii, polished surfaces, and uniform micro-hole sizes previously unattainable using electrical discharge machining (EDM) alone. In the spray orifices of diesel injector nozzles, both Extrude Hone AFM processes reduce variability produced from the manufacturing process thereby creating more precise flow.  The traditional AFM process improves fatigue strength by smoothly radiusing the fuel passages that break into the fuel gallery of an injection nozzle. By polishing surfaces and radiusing intersecting passages of fuel injector nozzles with AFM results in a smooth wall chamber with radiused fuel hole intersections. Prior to MicroFlow AFM process , precision orifices in fuel injectors and metering nozzles required a two-step finishing process in which they were first machined, and then in a separate process flow tested. With our advanced MicroFlow AFM process, Extrude Hone combined both critical and necessary steps into one automated and highly controlled process. Our MicroFlow AFM process is able to size and flow tune hole diameters down to 50 µm (0.002 inch) while preserving the dimensional integrity of the “seat” surface. The entry radius and finish improvements directly contribute to enhancing the flow capacity and durability of the orifice. Additionally, different flow conditions (i.e., higher discharge coefficient) can be adapted to provide functional product benefits. Flow rates of these orifices can be “tuned” to less than ±1% of total flow, which results in lower emissions and better fuel economy. MicroFlow AFM processing can be performed by either of two distinctly different methods, depending upon your needs: High Viscosity (HV) Media Processing or Low Viscosity (LV) Media Processing. While both methods achieve similar results, HV is more suited for processing multiple parts simultaneously while LV is ideal for achieving a target flow rate in a single step process. If you produce micro size holes that require close tolerances, controlled or uniform flow rates, and burr free operation, Extrude Hone AFM and MicroFlow AFM processes deliver the necessary surface finishes vital for enhanced atomization and flow characteristics:
Learn more about the Extrude Hone AFM and MicroFlow AFM processes.
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