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Fuel Injector Manufacturer Case Studies

Case Study # 1

Part Information:
  • Part Name
  • Bore Diameter
  • Bore Length
  • Bore Configuration
  • Diesel Fuel Injector Barrel
  • 9.00mm
  • 30.50mm
  • Thru-bore
Material Specifications:
  • Material
  • Hardness
  • 52100 Steel   
  • 60 Rc
Incoming Tolerances:
  • Bore Diameter
  • Stock to be Removed
  • Straightness
  • Roundnes
  • Parallelism
  • Surface Finish (Ra)
  • 8.903 +/-0.004mm                
  • 0.097mm
  • 0.003mm
  • 0.003mm
  • 0.0015mm
  • 1.1um Ra
Barnes Processing Machine & Tooling:
  • Model
  • Honing Work Stations
  • Honing Tool Abrasive
  • Honing Tool Abrasive
  • Coolant
  • HV1000-2
  • 2
  • B151 (Roughing)
  • B46 (Finishing)
  • Water-Soluble Emulsion         
Required Tolerances:
  • Bore Diameter
  • Straightness
  • Roundness
  • Surface Finish (Ra)
  • Parallelism
  • 9.00mm +/-0.001mm       
  • 0.001mm 
  • 0.001mm
  • 0.20-0.37um Ra
  • 0.001mm
Final Tolerances Achieved:
  • Bore Diameter
  • Straightness
  • Roundness
  • Surface Finish (Ra)   
  • Parallelism
  • Processing Time
  • 9.00mm +/- 0.0005mm
  • 0.0002mm
  • 0.0003mm
  • 0.25um Ra
  • 0.0012mm
  • 60 parts /hour (120 passes)

Case Study # 2

Part Information:
  • Part Name
  • Bore Diameter
  • Bore Length
  • Bore Configuration
  • Diesel Fuel Injector Barrel
  • 10.00mm
  • 40mm
  • Thru-bore
Material Specifications:
  • Material
  • Hardness
  • Nitrided Steel
  • 60 Rc
Incoming Tolerances:
  • Bore Diameter
  • Stock to be Removed
  • Straightness
  • Roundnes
  • Parallelism
  • Surface Finish (Ra)
  • 9.888 +/-0.007mm                 
  • 0.112mm
  • 0.01mm
  • 0.01mm
  •  0.0015mm
  • 0.9um Ra
Barnes Processing Machine & Tooling:
  • Model
  • Honing Work Stations
  • Honing Tool Abrasive
  • Honing Tool Abrasive
  • Coolant
  • HV1000-4
  •  4 (3 honing, 1 brushing)         
  • B151, B46, B10/20
  • Water-Soluble Emulsion
Required Tolerances:
  • Bore Diameter
  • Straightness
  • Roundness
  • Surface Finish (Ra)
  • Parallelism
  • 10.00mm +/-0.001mm     
  • 0.001mm 
  • 0.001mm
  • 0.05um Ra
  • 0.0012mm
Final Tolerances Achieved:
    • Bore Diameter
    • Straightness
    • Roundness
    • Surface Finish (Ra)   
    • Parallelism
    • Processing Time
  • 10.00mm +/- 0.001mm
  • 0.0003mm
  • 0.0005mm
  • 0.05um Ra
  • 0.05um Ra
  • 0.001mm
  • 36 parts /hour (144 passes)

Case Study # 3

Part Information:
  • Part Name    
  • Bore Diameter
  • Bore Length
  • Bore Configuration 
  • Diesel Fuel Injector Barrel
  • 10.50mm
  • 50mm
  • Blind, 9mm Relief
Material Specifications:
  • Material
  • Hardness           
  • Case Hardened Steel
  • 60 Rc
Incoming Tolerances:
  • Bore Diameter
  • Stock to be Removed
  • Straightness
  • Roundnes
  • Parallelism
  • Surface Finish (Ra)
  • 10.38 +/-0.007mm               
  • 0.120mm
  • 0.012mm
  • 0.012mm
  •  0.0015mm
  • 0.85um Ra
Barnes Processing Machine & Tooling:
  • Model
  • Honing Work Stations
  • Honing Tool Abrasive
  • Honing Tool Abrasive
  • Coolant
  • HV1000-5
  • 5 (4 honing, 1 brushing)
  • B151, B107, B46, B22/36
  • Water-Soluble Emulsion        
Required Tolerances:
  •  Bore Diameter
  • Straightness
  • Roundness
  • Surface Finish (Ra)
  • Parallelism
  • 10.50mm +/-0.001mm   
  • 0.001mm 
  • 0.001mm
  • 0.05um Ra
  • 0.0012mm
Final Tolerances Achieved:
  • Bore Diameter
  • Straightness
  • Roundness
  • Surface Finish (Ra)   
  • Parallelism
  • Processing Time
  • 10.50mm +/- 0.0005mm
  • 0.0003mm
  • 0.0005mm
  • 0.12um Ra
  •  0.0012mm
  • 24 parts /hour (120 passes
Barnes Honing 501 W. Algonquin Rd. Mount Prospect, IL 60056 | Ph: 866.907.6706 | Email: sales@barneshoning.com