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Fuel injectors operate under high pressure and high-frequency conditions, where small geometric deviations introduced during manufacturing can significantly affect long-term performance stability. While injector design optimization has been widely studied, the influence of manufacturing tolerances on injection consistency and durability remains insufficiently understood. This study investigates how dimensional variations in critical injector components impact long-term operating behavior.

Key components such as the nozzle orifice, needle valve, and control chamber are particularly sensitive to manufacturing errors. Minor deviations in nozzle hole diameter or roundness can alter fuel flow characteristics, leading to uneven spray distribution and injection quantity variation. Similarly, tolerance accumulation in the needle–seat interface affects sealing quality, increasing the risk of internal leakage and delayed closing behavior.

A statistical model is developed to evaluate the relationship between manufacturing tolerances and injector performance dispersion. Monte Carlo simulations are used to analyze the combined effect of multiple geometric parameters on injection rate stability. The results indicate that nozzle hole diameter variation is the dominant factor influencing injection quantity, while needle concentricity plays a key role in spray symmetry.

To assess long-term effects, endurance tests are conducted under cyclic high-pressure injection conditions. Injectors with larger tolerance deviations show accelerated wear at the needle seat, resulting in progressive injection drift over time. In contrast, injectors manufactured with tighter tolerance control maintain more stable injection characteristics and lower leakage rates throughout the test duration.

The study also examines compensation strategies to reduce the negative impact of manufacturing variability. Adaptive calibration techniques based on injector classification and electronic correction are shown to improve injection consistency without increasing production cost significantly. Additionally, selective assembly methods are proposed to match components with complementary tolerances, further enhancing overall injector uniformity.

The findings highlight the importance of integrating manufacturing quality control into injector performance optimization. Rather than relying solely on design improvements, controlling tolerance distribution and implementing effective compensation strategies are essential for achieving long-term injector reliability. This research provides practical guidance for injector manufacturing and quality assurance in high-performance fuel injection systems.