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Optimization Design of Diesel Injector Rocker Arm Based on iSight Platformm

Lin Xiankun;Wang Shuang;Li Jianhua;School of Mechanical Engineering, University of Shanghai for Science and Technology;Steyr Motors Co., Ltd.;  
Injector rocker arm is one of the key components to control fuel injection of engine. In the work process, it bears cycle load which leads to fatigue failure. So it is significant for the whole engine to possess an optimal structure in the rocker arm. Analysis of fracture in a conventional fork-type rocker arm is conducted. With the combination method of AVL Excite TD based analysis and experimental tests, the counterforce is acquired on the valve side of the arm. With finite element analysis of the rocker arm,the reason of the destructive fracture is obtained. Then a new rocker arm structure is presented on the basis of an updated finite element, which is integrated with iSight and Abaqus, with maximum stress of the rocker arm as the objective function and particle swarm optimization as the solver. In comparisons of strength, stiffness and fatigue resistance between the two rocker arm structures,the result shows that the new structure is superior to the conventional fork-type arm. Finally the result in a durability test shows the feasibility and advantage of the new structure.
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