In this research, a fuel injector nozzle for a diesel engine currently made by machining was identified as a candidate part for cold forging. This part was selected to study for manufacturability by forming because of the potential of major savings in machining if the part could be made by net shape forming and possible improvements in material properties owing to cold work. This paper presents the methodology used, the approach to precision and ejection issues and a possible forging/machining sequence for the fuel injector nozzle. This methodology is applicable to cold forging of other small precision parts.
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