Benseler: 100 millionth injector body ECM-machined and deburred

The non-contact ECM process (electrochemical metal machining) is used in particular where maximum precision is required: for the defined deburring of edges, the insertion of contours or the burr-free opening of holes. "Cooperation over such a long period of time is a special sign of trust. This milestone is therefore an event that we are particularly pleased about," explains Silvio Peschke, Managing Director at Benseler and responsible for the deburring division. Every year, several million injector bodies pass through the automated ECM systems at the Benseler site in Frankenberg. The process allows machining even in hard-to-reach areas without mechanical contact and without thermal stress on the workpiece. Benseler has been involved in the production of common rail technology since its beginnings - from simple injection systems to today's solutions. In the production process, the company is firmly integrated into the Schaeffler Vehicle Lifetime Solutions supply chain: The raw parts are taken directly from the machinist, stored and machined on demand on the company's own ECM automatic systems. These are specially adapted by Benseler to the customer's requirements. Finally, the parts are packed and dispatched.

Contactless opening and deburring of bores

Just like injection technology, the electrochemical metalworking of injector bodies at Benseler has evolved in line with growing technical requirements. The deburring specialists can draw on more than 25 years of experience. Currently, injector body machining is carried out in three steps: First, the workpieces are preconditioned using a classic high-pressure water jet deburring process. This is followed by the burr-free opening of the bores. An electrochemical reaction gently removes the material until the borehole has the desired opening - completely free of burrs and chips. In the third step, the components are cleaned, checked and packaged. In 2024, the range of services was also expanded to include the electrochemical machining of nozzle bodies - another part of the common rail injection systems from Schaeffler Vehicle Lifetime Solutions. "Deburring using the ECM process is ideal for rounding edges in precisely defined areas, especially in hard-to-reach places, with complex geometries or thin-walled and sensitive workpieces," explains Silvio Peschke. The material properties remain virtually unchanged and there are hardly any restrictions in terms of alloy or microstructure: Benseler can use this method to deburr cast, pressed and forged parts as well as hardened workpieces.