Laser drilled Injectors Instead of EDM??

[justinp20012500]

I read somewhere that EDM process is getting phased out. There is going to be new restrictions put on diesel and some manufacturers are going to lasers to "drill" holes in the injectors.



The laser can drill smaller holes, faster. (Smaller does mean less fuel, but maybe drill 12 holes instead of the standard 8. That could possibly mean better fuel atomization and hydraulically flow the same as a "regular EDM" injector)



Their laser can drill a hole in 1 second or less, compared to 12 second or longer that takes an EDM machine to drill a hole. (Potential cost savings passed on to the consumer?) Also the laser does the job without using the consumables that an EDM machine uses. (Also more potential to pass on cost saving to the consumer)



Read page #4. There is some great info there.





http://www.lambdaphysik.com/pdf/pdf_225.pdf



Go to products and click on micro drilling.



http://metalase.com/





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Justin "Just thinking outside the box"

 

[boonsur]

In my opinion, laser cannot touch EDM, for surface finish.



Also, there's got to be a point where clogging concerns override the atomization gain.

 

[Gary - K7GLD]

"In my opinion, laser cannot touch EDM, for surface finish. "





I dunno - that laser hole looks awful neat and round to ME - especially as compared to the oblong EDM hole displayed next to it...



Clogging MIGHT be an issue with smaller holes tho'...

 

[RonA]

Gary,

I think the hole is oval because the hole is rotated slightly away from view. I am also not sure about consistency from hole to hole with a laser. I have laser cutting done from time to time and even on thin material there is no comparison to edm work. Must be some new process. Also would be concerned with burring on inside due to melted metal rolling over into inside. would be faster and more profitable. That is probably the attitude behind it. Better to the end user means higher quality, better to the manufacturer means more profit. anyone notice the laser hole is shaped like the 5 sided mopar symble?

 

[JSykes]

I don't see that the laser will replace the EDM for injectors. We have a 5000 watt and a 2600 watt laser at work that are capable of cutting up to 1" thick steel yet we send work out to me EDM wire cut. Why? Because the EDM is more effecient at that type of work.



There are consumables associated with lasers. You have to use either a high purity oxygen or nitrogen to cut with. The lasers require high pressure gases to cut with. There are also lenses and diffuesers that have to be replaced.



Cost is another issue. Our new 5000 watt laser cost $650,000 versus $100,000 or so for an EDM machine. Have to make a lot of injectors to pay for that machine.



The laser also has a start/stop point on the inside of the hole. This leaves a "tic" mark on the inside of the hole.



My familiarity with lasers and EDMs are from sheet metal fabrication and tool and die building. I am by no means an expert.

 

[PRyker]

Ummm...



Guys, is it just me or does that EDM hole in the pic above look like it was added "AFTER" the pic was taken? In other words the pic has been doctored up.



Phil

 

[Cooker]

The laser can drill smaller holes, faster. (Smaller does mean less fuel, but maybe drill 12 holes instead of the standard 8. That could possibly mean better fuel atomization and hydraulically flow the same as a "regular EDM" injector)

More is not necessarily better. Cummins went back to 5 holes in the 04. 5 engines. With the upmost concern with emissions I don't know why they would step back in number is the more numerous smaller holes means better atomization. Just a thought.



boonsur,

It is good to see you are still around

 

[justinp20012500]

Ummm...



Guys, is it just me or does that EDM hole in the pic above look like it was added "AFTER" the pic was taken? In other words the pic has been doctored up.



Phil

DId you click the links???



I pulled the picture directly from the website.

 

[justinp20012500]

Did you know that one of the highest HP 12V injectors that had 12 holes in them???

 

[Gary - K7GLD]

"I pulled the picture directly from the website. "



And if you follow and read ALL the pointers - as well as photos, you get a better idea of the "big picture"...

 

[RonA]

I read the article. Interesting. I've got a few old nozzles down at the shop. I think I'll mill the tip in half and look at it under the microscope. I have wondered about the thickness of the tip where the holes are.