The sophisticated common rail direct fuel injection system is a far better version of the classic direct fuel injection system. It is considered to provide the most reliable and clean way to inject fuel into the combustion chamber. The modern automotive industry appreciate it because of its fuel efficiency and emission-controlled technology. The constantly growing number of diesel-powered cars in Europe and the new markets in USA and Asia require reliable technology and best emissions performance. Only the direct fuel injection system fulfill these expectations and is in the position to be at the forefront of environment friendly technology, while enhancing fuel economy and reducing noise level due to cleaner combustion.
The common rail direct fuel injection system consists of shared fuel reservoir (common rail) and electronically controlled injectors. After the fuel has been stored under heat and pressure in the common rail, the system injects precise amounts of fuel into the combustion chamber and makes high injection pressure available at all times.
The common rail is a vital component in the entire system that is exposed to extreme conditions, but always expected to perform flawlessly. In order to meet all mentioned requirements and to deliver best quality, Setforge Group provides high-resistant common rails, manufactured according to latest technologies.
By following all new trends, Setforge delivers perfection in:
1. Raw Material Selection:
By using forged aluminum and stainless steel, we secure the most reliable performance of Setforge common rails. Both, aluminum and stainless steel possess corrosion resistance and thanks to a wide range of alloy options combined with different heat treatments, they can achieve a broad range of mechanical properties.
By anticipating any possible performance problem, the Setforge common rails are designed to overcome any obstacle. Through accurate measurement and testing, our team of experienced engineers develop process and product design that guarantee resistance and reliability. The entire tooling requires specific size of workpiece, which if not well determined during the design phase, will cause plenty of defects on the metal's surface (link to the article: A Better Design for a Perfect Common Rail Perfomance). In order to make it also possible for the common rail to handle later the desired fuel volume level, the exact dimensions of length and section diameter (link to the article: A Better Design for a Perfect Common Rail Perfomance) should be given in the very first stage of the design.
3. Manufacturing process:
Setforge is convinced that only common rails manufactured through forging ( a link “5 Good Reasons to Choose Forged over Machined Common Rails) can meet requirements and deliver best performance. Forging strengthens the metal by using localized compressive forces and make it far more resistant than the equivalent machined part. The manufacturing process of Setforge common rails consist of two shaping steps that guarantee strength, resistance and reduced to the minimum material loss. After the component has been roll forged to define the basic shape, an upset or hot forging is used to finalize the final size.
Setforge manufactures all sizes of hot, semi-hot or cold forged common rails by selecting the best materials and maximizing product and process design. Our engineers combine professionalism and experience with latest trends and innovation. We work closely with the customer to optimize performance, cost and weight and to provide best solutions tailored to meet individual needs.