In manufacturing of any engine component a thorough analysis of the process is vital in order to avoid defects in the component. A general approach to the computer modeling and analysis of material handling and manufacturing processes for engine components, in particular spark plugs, is presented. In the first part of this paper the insulator grinding process is modeled as a dynamically balanced load configuration. The loading of the robot arm on the green insulator is modeled as an impulse moment. In the process of transporting the part, the traveling loads in conveyers and stops are modeled as impulses and shock loads. Finite element models of a green insulator were created and subjected to the dynamic loads in the material handling processes. The models were analyzed using the nonlinear finite element code ABAQUS [
In the second part of the paper the assembly process of the fired insulator is modeled and analyzed. The tamping of the glass powder is modeled by considering the powder to be a granular material subjected to a punch load. The nonlinear finite element analysis of the process of pushing the terminal screw at high temperature was performed using ABAQUS. The residual stresses due to the cooling process were determined. Finally, the results and discussion of some processes are presented.