"A 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," says Silvio Peschke, Managing Director of Benseler. He is responsible for the deburring division. Every year, several million injector bodies pass through the automated ECM systems at the Frankenberg site. The process allows machining even in hard-to-reach areas without mechanical contact or thermal stress on the workpiece.
Firmly integrated into the supply chain
Benseler has been involved in the production of common rail technology since its inception. The company is firmly integrated into the Schaeffler Vehicle Lifetime Solutions supply chain: The raw parts are taken directly from the machinist, stored and processed on call on the company's own ECM automatic systems, which are adapted by Benseler to the customer's requirements. Packaging and dispatch follow at the end.
Contactless opening and deburring of bores
Just like injection technology, the electrochemical metalworking of injector bodies has evolved in line with growing technical requirements. Injector body machining currently takes place in three steps: a classic high-pressure water jet deburring process first preconditions the workpieces. The holes are then opened without burrs. An electrochemical reaction gently removes the material until the borehole has the desired opening. 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.
Also for complex geometries and hardened workpieces
"Deburring using the ECM process is ideal for rounding edges in precisely defined areas, especially in hard-to-reach places, complex geometries or thin-walled and sensitive workpieces," says 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.