Bosch and GE Additive collaborate on metal AM engine part

February 18, 2018

Bosch and GE Additive collaborate on metal 3D printed engine part

The final metal additively manufactured oil header (Courtesy GE Additive)

 

GE Additive reports that it has collaborated with the automotive parts team at Bosch in Bamberg, Germany, to redesign and additively manufacture a metal oil header for use in a common rail injector (CRI) on a diesel engine. The result was a consolidation of the header from two parts to one and the elimination of lubrication blind spots.

With conventional diesel injection systems, fuel pressure has to be generated individually for each injection. Conversely, in CRIs, pressure generation and injection are separate, meaning that diesel fuel is constantly available at the required pressure for injection.

According to Bosch, it has become increasingly important that newer generations of CRI, which have different surface properties, are lubricated on the outside diameter of the thread to prevent friction. In a recent examination of the oil process during CRI assembly at Bosch’s Bamberg plant, the part was found to have ‘lubrication blind spots’.

Dr Anna Ebert, who is responsible for CRI assembly at the plant, discovered that the component was wet with oil only on the upper thread geometry and not on the bottom side. Initially, the team attempted to rectify this with a redesign of an oil header in three or four parts using conventional machining, but reportedly found this approach too complex and cost-prohibitive.

 

Bosch and GE Additive collaborate on metal 3D printed engine part

By re-engineering an oil header for AM, Concept Laser reduced the component from two parts to one (Courtesy GE Additive)

 

On deciding to explore metal AM for the redesign, the team partnered with Concept Laser, a GE Additive company. The conventional design was assessed by Concept Laser and a new design created incorporating a new geometry for the oil channels, for production in CoCr. Though a Concept Laser M2 cusing system was already installed at Bosch’s Nuremberg facility, a smaller Mlab cusing system was selected as the more suitable choice to produce the oil header due to the part’s size and complexity.

Having tested the redesigned component, Dr Ebert stated, “The process fluctuations were visibly smoothed out. The 3D printed oil header was much better at delivering the right amount of oil to the right place.” She reported that wetting now takes place not just at the top of the thread, but also at the bottom, meaning that the lubrication blind spots identified in the previous design have been eliminated in the new header.

“The new oil header looked different – smaller and more compact,” added Wolfgang Schliebitz, Production Planner at Bosch in Bamberg. “But what was really surprising was the effect on our process during trials.” GE Additive reported that the redesigned component has now been introduced to four other Bosch plants in Korea, Turkey, Germany and France.

www.ge.com

www.concept-laser.de

www.bosch.com

 

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 176-page issue includes articles and reports on:

  • Innovation and differentiation: Precious metal Additive Manufacturing in the jewellery sector
  • Unrealised potential: The story and status of Electron Beam Powder Bed Fusion
  • Freemelt AB: Open source technology to explore the potential of Electron Beam Powder Bed Fusion
  • In pursuit of perfection: A case study on how Bugatti and APWORKS leverage the full potential of AM
  • Facing obstacles to profitability in metal AM: An Operational Excellence perspective
  • Mass-production using PBF-LB: How laser beam measurements can help pave the way
  • Link3D’s ‘Additive Manufacturing Maturity Model’: Developing an agile and resilient supply chain
  • Design for Additive Manufacturing (DfAM): Binder Jetting Technology demystified
  • > More information

Latest news

    E-newsletter

    Sign up to our e-newsletter, sent weekly to AM professionals and end-users around the world. We'll also let you know each time a new issue of Metal AM magazine is available.

    Discover our magazine archive…

    The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:
    • Reports on visits to leading metal AM part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news
    All past issues are available to download in PDF format, in either single page format or as double-page “spreads” for viewing on large monitors. All downloads are free of charge. Go to archive...

    Connect with us

    Visit our social media channels and sign up to our e-newsletter

    Copy link
    Powered by Social Snap