Modeling and analysis of a fuel-injection pump used in diesel engines

The Fuel-Injection Pump (FIP) used in diesel engine has a higher-pair cam-mechanism to pressurize the fuel for injection. This paper proposes a methodology to model FIP from a multibody Dynamics (MBD) perspective. The results from the model include the temporal behavior of driving torque, contact Hertz stress and reaction forces at various joints. The model helps the designer to assess the effect of various cam profiles, link parameters and other design variables. It is necessary that these parameters be optimized for future high pressure applications. For this purpose, a cam-mechanism with offset follower axis is analysed. Decoupled Natural Orthogonal Complement (DeNOC) matrices based algorithm is used to model FIP without and with offset cam-mechanism. The study shows that, the offset cam-mechanism allows reduction in the side-thrust, reaction forces, and the contact Hertz stress acting on the cam-follower interface. As a typical case, for an FIP working around a pressure value of 600 bar, an optimum offset value is found to be 9.5 mm and it shows a reduction of about 45% in side thrust values. To validate the modeling approach, experimental studies are performed on pump without and with offset cam-mechanism. Experimental results are in qualitative agreement with the theoretical model results.