Cam Shaft Research Articles

Effect of boronizing composition on hardness of boronized AISI 1045 steel

Surface hardening process of cam shafts manufactured from AISI-1045 Steel was provided by boronizing in liquid and solid media. To boronize in liquid and solid medium, various chemical agents were used. At this study, research was conducted on hardness and thickness of the layers obtained according to the boronizing composition. The effects of boronizing bath compound on the quality of the layers obtained are being disputed. It is understood that 70% Borax (Na2B4O7) + 30% B4C is the most suitable boronizing compositions in the liquid medium to obtain the hardest and thickest borid layer on AISI-1045 steel samples. For solid media boronizing, the combination was determined as 5% B4C + 90% SiC + 5% KBF4.

Development of a novel rotary flow control valve with an electronic actuator and a pressure compensator valve for a gas turbine engine fuel control system

This paper presents a new rotary proportional flow control valve with Cam-Nozzle configuration. The rotating cam against the fixed nozzle changes the flow area and then can meter the fuel flow. This valve equipped with a pressure compensator plunger type valve to retaining constant pressure difference across the flow control or metering valve. The cam shaft directly coupled to an electronic servomotor type rotary actuator and then it is possible to apply digital control techniques such as pulse width modulation (PWM) in this control system. This new valve configuration is developed for an electro hydro mechanical fuel control system in a gas turbine engine. In addition to aero engine application, this type of flow metering valve can widely be used in industrial hydraulic systems. In this unit, the output flow is proportional to the cam's angular position (or throttle command) and it is not sensitive to pressure fluctuations at nozzle inlet and outlet. The aim of this new design is to modify a manual single adjusted hydro-pneumatic fuel control unit to obtain a new electro-hydraulic fuel control system for a gas turbine engine. The main innovations in the presented fuel metering unit include new design of the rotary valve opening shape (Cam-Nozzle) without metal to metal contact, use of a rotary electronic actuating mechanism and also direct coupling between the actuator and the rotating cam. The increased fuel metering precision in the new flow control valve has improved the ultimate control accuracy of system. A computer simulation software based on the proposed model, is performed to predict the steady state and transient performance and to analyze effect of important design parameters on valve outlet fuel flow and obtain the final design parameters. The validity of the proposed valve configuration is assessed experimentally in the steady state and transient modes of operation. The results show good agreement between simulation and experimental in both modes (max. 4% deviation).

Experimental investigation on the machinability of nodular ductile iron with cubic boron nitride and tungsten carbide inserts

The nodular irons have more ductility which is demanded by mechanical components like crankshaft, cam shaft, bearing cap and clutch housing, offering fatigue resistance for their intended performance. The impact of various process parameters like depth of cut (D), cutting speed (S) and feed (F) on the cutting force of nodular iron was studied and optimized by using the RSM model. The nodular iron was turned at dry condition with two different types of cutting tools, namely CBN and coated tungsten carbide tool (TiCN + Al2O3 + TiN) to evaluate the influence of cutting parameters. The cutting speed employed for these tests are 102,174 and 245 m/min with feed rates of 0.051, 0.102 and 0.143 mm/rev together with the depth of cuts as 0.5, 0.75 and 1 mm. The tungsten carbide coated tool performed well as compared to CBN tool while machining with nodular iron in terms of getting lower cutting force and better surface roughness.

Hard Turning Cutting Tool Materials used in Automotive and Bearing Manufacturing Applications – A review

Hard turning for the machining of hardened steels by using super abrasive cutting tool materials is a comparatively newer manufacturing technology. Due to phenomenal advancements in super abrasive tool materials and machine tool technologies, hard turning becoming a potential alternate machining process to the traditional grinding. Hard turning offers many distinguished benefits over grinding process including fewer machining setups, shorter manufacturing time, lower manufacturing cost, achieving grinding comparable product quality. Fewer machining setups bring higher manufacturing flexibility, and lower the investment cost in machine tools in comparison to grinding. It is possible to carryout hard turning without coolant that eliminates the detrimental effect of coolants on the human health and environment. These benefits made hard turning a popular alternative for the automotive and bearing manufacturing industries for machining of cam shafts, gears, crank shafts, bearings, dies and mould. This paper reviews the researches that were performed on hard turning using cutting tool materials; cemented tungsten carbide (WC), poly-crystalline cubic-boron-nitride (PCBN) and ceramics. The research findings related to the effect of cutting parameters, tool geometry and surface coating on the tool life and tool wear phenomena of these hard turning tool materials in the hard turning of major steels used in automotive and bearing manufacturing industries have been discussed.

Improving the reliability and efficiency of tillage machines

Increasing the efficiency of diesel equipment operation is primarily associated not only with increasing the reliability of its main components, assemblies, joints and details, but also with reducing costs and fuel consumption during production processes. At the same time, operating experience shows that a significant share of the operating time of the equipment is not fully loaded, often up to 40 … 50%. The transient and unsteady modes that arise in this case, as well as the design features of the fuel equipment of domestic diesel engines, lead to an excessive consumption of fuel and a significant increase in the unevenness of fuel supply through the engine cylinders up to 26 … 38%. To ensure a minimum clearance in the plunger pair, it is proposed to apply a diamond-like thin film coating based on silicon oxycarbide onto the working surfaces of the details, which has high microhardness, low friction coefficient, and prevents the setting of contact surfaces by final plasma hardening. After applying the technological operation of hardening the working surfaces of the details by forming a thin film coating, the distribution of the parts over the time of crimping changed so that 82% of the experimental plunger pairs have a hydraulic density exceeding t = 45.7s with an average value of 46.7s with a mean square deviation σ = 1.05s. The results obtained during the tests showed that at the nominal speed of rotation of the cam shaft, the cyclic feed of the produced plunger pairs decreased by 2.8%, while in the experimental ones, the decrease in fuel supply was 1.3%, the uneven fuel supply in both cases did not exceed 2%. The predicted resource of the experimental plunger pairs will be 9000 hours, which is 2.25 times longer the resource of serial plunger pairs.

Improving the reliability of plunger pairs of diesel engines

Increasing the efficiency of diesel equipment operation is primarily associated not only with increasing the reliability of its main components, assemblies, joints and parts, but also with reducing costs and fuel consumption during production processes. At the same time, operating experience shows that a significant share of the operating time, the equipment is not fully loaded, often up to 40…50%. The transient and unsteady modes that arise in this case, as well as the design features of the fuel equipment of domestic diesel engines, lead to an excessive consumption of fuel and a significant increase in the unevenness of fuel supply through the engine cylinders to 26…38%. To ensure a minimum clearance in the plunger pair, it is proposed to apply a diamond-like thin film coating based on silicon oxycarbide onto the working surfaces of the parts, which has high microhardness, low friction coefficient, and prevents the setting of contact surfaces by finishing plasma hardening. After applying the technological operation of hardening the working surfaces of the parts by forming a thin film coating, the distribution of the parts over the time of crimping changed so that 82% of the experimental plunger pairs have a hydraulic density exceeding t = 45.7 s with an average value of = 46.7s with a mean square deviation σ = 1.05s. The results obtained during the tests showed that at the nominal speed of rotation of the cam shaft, the cyclic feed of the produced plunger pairs decreased by 2.8%, while in the experimental ones, the decrease in fuel supply was 1.3%, the uneven fuel supply in both cases did not exceed 2%. The predicted resource of the experimental plunger pairs will be 9000 hours, which is 2.25 times more than the resource of serial plunger pairs.

THE RESEARCH OF PARAMETERS OF WORK OF ROTOR-PISTON ENGINE

The direction of application of compressed air energy in various industries and transport is developing at a fairly intensive pace. The biggest drawback when using an air motor is the low energy efficiency of the working fluid, that is, the specific air consumption per kilowatt of generated energy. The design and basic parameters of the new rotary-piston engine 12RPE-4,4/1,75 with adjustable spool air distribution are presented. The engine has twelve cylinders evenly spaced, which ensures the balance of the engine and the ability to start at any position of the rotor. The proposed scheme of the mechanism of motion provides a fairly simple and compact design of a rotary-piston engine, with the value of the relative dead volume εo due to only technological gaps and slightly (εo = 0.015). The engine design provides for the presence of a central regulating cam shaft, the rotation of which allows adjusting the valve timing and engine operating modes due to the degree of filling of the cylinder ε1 over a fairly wide range. Thus, the values of the degree of filling of the cylinder are in the range of 0.135...0.175. With a decrease in the degree of filling ε1, a decrease in the specific consumption of compressed air is observed with a certain drop in the average indicator pressure due to a decrease in the area of the indicator diagram. The primary assessment and analysis of the influence of the main parameters of the air motor on the efficiency of energy conversion in a rotary-piston engine of a new design were carried out. Indicator diagrams for different values of working fluid pressure at the entrance to the rotary-piston engine are given. The pressure value of the working fluid at the inlet varied within 1.0...1.9 MPa, while the indicator engine power was 0.91...1.62 kW. The dependence of changes in the indicator indicators of the 12 RPE-4,4/1,75 engine, such as power, specific air consumption, average pressure and indicator efficiency, is given. It was established that, depending on the load of the rotor-piston engine, the specific indicator air flow rate is 29.9...18.4 kg/kW∙h, while the indicator efficiency varies within 0.47...0.83.

A study on the improvement of the cam phase control performance of an electric continuous variable valve timing system using a cycloid reducer and BLDC motor

This paper discusses the control performance improvement for an electric-continuous variable valve timing (E-CVVT) system using a brushless direct current (BLDC) motor and cycloid reducer. Each component of the E-CVVT system was implemented with mathematical analysis, and the response performance of the E-CVVT system was determined based on the mathematical model of the cam shaft motion, cam profile, cycloid reducer, BLDC motor, and controller. To control the intake valve timing of the engine, a cycloid speed reducer with a high reduction ratio capable of amplifying the output torque of a small BLDC motor was implemented. The change in valve speed due to the rotation of the cam shaft was represented by the curves described by the vertical movement of the valve using the cam profile. A control performance test apparatus was constructed and the torque of the intake cam shaft was measured and applied to the analysis so that the phase of the cam shaft could be changed using the E-CVVT system. To analyze the operating characteristics of the E-CVVT system, the BLDC motors were modeled using Simulink. The E-CVVT system controls the phase angle of the intake cam shaft. When the E-CVVT system sets the target phase angle, the motor controller generates the optimal motor speed command. The intake cam phase response speed depends on the setting of each PID parameter that changes the phase of the cam shaft. Through analysis and vehicle-based experiments, we confirmed the improvement of the E-CVVT system response performance according to the change of the PID parameter.

INFLUENCE OF THE METERING METHOD ON THE CHARACTERISTICS OF A DIESEL DISTRIBUTOR FUEL PUMP

Objectives The aim of the study is to improve the performance of the metering system and thus enhance control over the cyclical supply of fuel to a diesel distributor pump. The results of a study of the effect of a new metering method on the characteristics of a distributor fuel pump are presented. Methods Following mathematical analysis, a mathematical model of the working process of the fuel supply system, based on a new metering approach employing the "decay of discontinuity" method, was compiled.The model comprises a system of differential equations for continuity and momentum alongside mass balance equations for describing the boundary conditions for various cavities of the fuel system, i.e. above the plunger, under the valve, above the valve cavities and in the nozzle. The differential equations take into account the two-phase nature of the gas-liquid medium in the injection cavities and metering system, as well as the design features of the pump. An expression for the stroke of the metering plunger in the new system is given. Results The theoretical and experimental characteristics of a fuel supply system employing the proposed metering system are considered. Diagrams showing maximum injection pressures, which depend on the stroke of the metering plunger at various strokes of the injection plunger and alteration of maximum injection pressure of the nozzle depending on the rotation speed of the cam shaft, are provided. The characteristics of the fuel supply system of the pump for various spring stiffness of the metering plunger are also provided in diagram form. The comparative parameters of the fuel supply process are presented for the conventional and new metering methods. The features of the use of diesel high-pressure distributor pumps, their design and operational features are described. The advantages of the metering system proposed by the author are presented in terms of its influence on the fuel injection process. A comparative evaluation of metering methods used in contemporary distributor pumps for diesel engines is given. Conclusion The results of the experiments confirmed the suitability of the new metering method for use in diesel engines.

Implementation of MCDM model in lean manufacturing using grey relational analysis in automotive industry

The present economic situation shows the consistent demand for profitable solutions that allow business organizations to gain better ad-vantage. Due to this reason, many organizations search for methodologies that allow them to improve their products and services improve their processes, reduce costs, and improve the profit and customer satisfaction. This has been implemented through lean techniques in their managerial and production methods. As we know Lean production system mainly emphasizes on the waste elimination, using simple and visual techniques. This paper is an attempt to optimize process layout and waste expulsion for automotive powertrain in a leading automo-tive company by using lean manufacturing techniques. In this paper, the existing process in place for machining of cam shaft is analysed and process layout is optimized to reduce cycle time and lead time. In order to reduce the cycle time, the process parameters such a speed, feed and depth of cut are optimized for increased material removal rate (MRR) and decreased surface roughness (RA) by using Grey Relational Analysis (GRA) technique. As MRR is inversely related to cycle time, optimization of parameters for higher MRR reduces the cycle time. Grey Relational Analysis is done by using Design Xpert software.

Improvement in Millipore and Implementation of Pneumatic System for Burr Removal

Each component or a part which is nature or arranged by human has an end period or disillusionment time. We as masters influence an average endeavor to find the life to time and make various arrangements to diminish the failure and augmentation the life time. Machining is improved the situation screws, Cylinder heads, Cylinder block, crank cases, cover cases and crank and Main Bearing (MB) Caps. Throwing is improved the situation cam shafts and motor external bodies. Every part component has a remarkable request of handling. It takes after and request of either throwing or manufacturing and machining. Furthermore, in view of the tainting in the motor, the motor keeps running with a considerable measure of issues like wear and tear, Huge clamor, Friction, Vibration and so on, of interior parts of the motor. These burrs are the main consideration for the sullying caused in the motor get together. Because of this client disappointment is going high. To control this specific strategy are taken after and kept up.

Analysis of Cam and Crank Shaft Gear Material for Single Cylinder Petrol Engine

Analysis of Cam and Crank Shaft Gear Material for Single Cylinder Petrol Engine

Early Injected PCCI Engine Fuelled with Bio Ethanol and Diesel Blends – An Experimental Investigation

Abstract In this paper the work deals with the Experimental analysis of the early direct injected PCCI. For this investigations, the neat diesel and bio ethanol - diesel blend (E20) fuels were used as fuel and the pressure, combustion and emission characteristics were studied in the equivalence ratio of 0.6 (ɸ = 0.6). The injection timing was advanced to 18° rather than the normal 23° before top dead centre (BTDC) as specified engine conditions. For the Experimental analysis the partial homogeneity of the charge was achieved by injecting the fuel in the pre chamber which consists of a heater unit. The fuel injection timing was controlled with respective to the crank angle timing with the help of an ECU unit. In the pre chamber the fuel was vaporised and the partial homogeneous charge was fed in to the engine during the suction stroke. The injection timing was advanced by removing shim from the cam shaft rocker arm mechanism of the engine. The results of the neat diesel and bio ethanol diesel (E20) blends were compared and oxides of Nitrogen were reduced to very lower levels when compared to neat diesel operations.

PREDICTION AND INVESTIGATION OF SURFACE ROUGHNESS WHILE TURNING SG IRON WITH CUBIC BORON NITRIDE (CBN) AND TUNGSTEN CARBIDE INSERTS

This work compares the effect of cubic boron nitride (CBN) and multilayer (TiCN+Al2O3+TiN) coated tungsten carbide (WC) tools during the turning of spheroidal graphite (SG) nodular iron. Nodular irons have more ductility which is required in mechanical components that demand high fatigue resistance like crankshafts, cam shafts, bearing caps and clutch housings. The impact of various process parameters like the depth of cut, cutting speed and feed on the surface roughness (Ra) of SG iron is studied and optimized using the response surface model. The chip morphology is also discussed for evaluation of the quality of the turned surface. The experimental outcomes reveal that the WC tool offers a high surface finish at the optimal combination of the cutting speed at 102 meter/minute, feed at 0.051 millimeter/revolution and depth of cut at 0.5 millimeter and that, for the CBN insert, at 245 meter/minute of cutting speed, 0.051 millimeter/revolution of feed and 0.75 millimeter of depth of cut.

An Analytical Investigation On Design And Structural Analysis Of Cam Shaft Using Solid Works And Ansys In Automobiles

Objectives: This paper reports an investigation that was carried out for modelling and structural analysis of cam shaft. Methods/Statistical Analysis: The modelling of cam shaft is carried out using the software solid works and the structural analysis of the model is carried out by using Ansys software. Initially, the model is designed with Solid works software and then it is converted into Initial Graphics Exchange Specification (IGES) file. Then it is systematically analyzed using the IGES model of cam shaft. Experimental results under static load containing the stresses and deflection are predicted cast iron material. Findings: Testing was carried out for unidirectional different materials like ductile cast iron, nodular iron and carbon epoxy. By considering these materials, it is noted that the ductile cast iron is a good material compared to the nodular iron because the breakage of nodular cast iron is higher than the ductile cast iron. Application Improvements: Ductile cast iron is considered for making the cam shaft in vehicles because the cost of material slightly higher than nodular iron. In the development of modelling and also analyse by software helps to better result in design.

Camless Engine using Laser LDR Circuit

This Paper gives an overview about the latest camless engine designed using laser LDR circuit. Engines that are being used in today’s automobile consist of a cam shaft which lifts up and closes the fuel inlet and outlet valves of the engine. Due to the inefficiency of the cam shaft to open up and close the engine fuel valves on time, it does not follow the ideal valve timing diagram and gives less output power and fuel economy then the calculated one. Lack of efficiency to open up and close the engine valves on time also result in presence of hydrocarbon and unburnt fumes in the engine exhaust. In order to overcome all these inefficiencies, a camless engine is developed in which the valves of the engine are actuated hydraulically with the help of a laser LDR Circuit. In the proposed system a laser LDR circuit is fitted over the crank shaft of the engine which senses the exact time of opening and closing of engine valve. The developed engine gives better power output and fuel economy by making the engine to follow the ideal valve timing diagram and hence eliminates all the inefficiencies of the engine by making today’s automotive engines more environment friendly by producing less hydrocarbons and unburnt fumes. The newly developed camless engine can be used in any type of automobile which uses IC engine as a power unit.

Effect of heat treatment on the tensile properties of cam shaft made of ductile cast iron

Effect of heat treatment on the tensile properties of cam shaft made of ductile cast iron

The prediction of combustion behavior and pollutant species by changing intake valve closure time

Using the finite‐volume method, the relations between different cam shafts profiles have been derived while the intake valve opening time and maximum lift are equal and the engine is equipped with a turbo charger. For this purpose, all equations are solved in one dimensional GT POWER and three‐dimensional AVL FIRE software. The results, such as engine performance and in‐cylinder pressure and temperature are presented. They show that with earlier intake valve closure, it is possible to decrease maximum in‐cylinder pressure as well as maximum temperature, while engine output variation is negligible. Concerning emission species, NOx—as one of the most important emissions in gas engines—is almost reduced by half by reduction in intake valve opening time, although the amount of both unburned hydrocarbon and carbon monoxide shows an increasing trend. © 2016 American Institute of Chemical Engineers Environ Prog, 35: 786–793, 2016

Effect of chill formation on the mechanical properties and microstructure of grey and nodular cast irons used in automotive industry

Cam shafts used in automobiles are produced by cast iron (grey cast iron, nodular cast iron) or steel. In this study, effect of chill formation on the surface of grey and nodular cast irons is investigated on the wear behavior, hardness, impact toughness and microstructure of grey and nodular cast irons. For this purpose, four types cam shaft made of grey cast iron with and without chill on the surfaces and nodular cast iron with and without chill on the surfaces, were casted. Mechanical tests were conducted after the camshafts have been produced by casting method. Surface hardness and wear resistance of grey and nodular cast irons have been improved by chill formation on the surfaces and it is concluded that the amount of wear on the surfaces of grey cast iron with chill and nodular cast iron with chill is almost the same. Maximum hardness value was obtained on the surface of grey cast iron with chill. The impact toughness has been found to decrease by chill formation. Maximum impact toughness value was obtained on nodular cast iron. Microstructures of grey cast iron with and without chill and nodular cast iron with and without chill were examined under optical microscope and worn surfaces of cast irons were examined by scanning electron microscopy (SEM). Wear mechanisms of the four types of cast iron were evaluated by SEM examination. Keywords: Cam shafts, Cast irons, Chill formation, Mechanical properties, Microstructure

Study of Inductive Sensors for Automotive Applications

There is an ever increasing demand for use of inductive speed sensors in a broad range of applications. They are used in typical applications such as cam and crank shaft position/speed and wheel and turbo shaft speed measurement. This paper describes the type of inductive sensor found on vehicles and the difficulties of detecting at low speeds. In the laboratory of Mechatronics an experimental device has been done to measure the speed using an inductive speed sensor. The experimental results are satisfactory and show the possibility of the inductive sensors to be used in automotive industry.