The increasing deployment of high-pressure fuel injection systems in modern internal combustion engines—particularly in aerospace and heavy-duty automotive sectors—has escalated the demand for robust, high-integrity component interfaces that can withstand extreme vibration and thermal stress. Inlet Metering Valves (IMVs), as critical control elements for fuel regulation, are frequently subjected to high-frequency vibrations and pressure pulsations. Traditional joining techniques, such as brazing and adhesive bonding, often fall short in maintaining dimensional stability and leak-tightness under such conditions. This study presents the design, development, and validation of a novel rolling crimping tool intended for mechanically securing IMV housings in high-vibration fuel systems. The crimping approach employs a dynamically profiled roller die that imparts uniform radial compression around the IMV perimeter, enhancing both the mechanical lock and sealing performance without introducing thermal distortion or metallurgical changes.
A multidisciplinary methodology combining CAD modeling, finite element stress analysis, precision CNC machining, and experimental vibration testing was adopted. Material selection was guided by tribological performance under cyclical loading, while geometric optimization focused on reducing peak stress concentrations in the crimp zone. Full-scale validation was performed using a custom-designed vibration rig simulating operational engine conditions, including harmonic excitation and thermal cycling. The results demonstrate that the rolling crimp technique significantly improves joint fatigue life, dimensional retention, and leakage resistance when compared to conventional methods. Statistical reliability analysis confirmed high repeatability across multiple prototypes, suggesting strong potential for scalable manufacturing and in-field adoption.
By addressing both structural durability and manufacturability, the proposed rolling crimping tool framework provides a compelling solution for fuel system designers seeking enhanced mechanical reliability in extreme environments. The study contributes to the broader engineering discourse on mechanical joining strategies for vibration-sensitive fluidic components and establishes a replicable pathway for quality assurance in high-risk applications.