Analysis of fatigue characteristics on camshaft using finite element analysis

Abstract

Camshaft plays an important role in the internal combustion engine, where it regulates the opening and closing time of the valves to allow fuel and air mixture to enter the engine and exhaust. The study aims to analyze the fatigue characteristics of the camshaft made from gray cast iron and cast carbon steel. SolidWorks and ANSYS Workbench were used to design and predict the lifespan of the camshaft. The modelled camshaft was used to analyze the fatigue properties. Modal analysis was performed to evaluate the deflections and natural frequency of the camshaft while static structural analysis used to evaluate the total deformation, maximum stress, and safety factor. Appropriate mesh size was used where the component was divided into several discrete parts or finite elements. The camshaft was assigned with boundary conditions such as fixed support and moment. Dunkerley’s approach was used to compare simulated natural frequencies to theoretical values. The resulting S-N curve plots the alternating stress on the camshaft against the number of cycles required to fail. Cast carbon steel was suggested to be the more desirable material since it can withstand 260 MPa of stress for 10 million cycles, whereas gray cast iron can endure only 140 MPa.