ISSN 2348–2370 Vol.09,Issue.05, April-2017, Pages:0651-0654

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Design and Manufacturing of a Camshaft Used in Multi Cylinder Engine

DR. CH. S. NAGA PRASAD Professor & Principal, Dept of Mechanical, GIITS Engineering College, Aganampudi, Visakhapatnam(Dt), AP, India, Email: [email protected].

Abstract: The cam shaft and its associated parts control the It is often a part of a rotating wheel (e.g. an eccentric wheel) opening and closing of the two valves. The associated parts or shaft (e.g. a cylinder with an irregular shape) that strikes a are push rods, rocker arms, valve springs and tappets. It lever at one or more points on its circular path. The cam can consists of a cylindrical rod running over the length of the be a simple tooth, as is used to deliver pulses of power to a cylinder bank with a number of oblong lobes protruding steam hammer, for example, or an eccentric disc or other from it, one for each valve. The cam lobes force the valves shape that produces a smooth reciprocating (back and forth) open by pressing on the valve, or on some intermediate motion in the follower, which is a lever making contact with mechanism as they rotate. This shaft also provides the drive the cam. to the ignition system. The camshaft is driven by the II. LITERATURE REVIEW crankshaft through timing gears cams are made as integral DESIGN AND ANALYSIS OF CAM SHAFT FOR parts of the camshaft and are designed in such a way to open MULTI CYLINDER ENGINE and close the valves at the correct timing and to keep them The cam shaft and its associated parts control the open for the necessary duration. A common example is the opening and closing of the two valves. The associated camshaft of an automobile, which takes the rotary motion of parts are push rods, rocker arms, valve springs and the engine and translates it in to the reciprocating motion tappets. It consists of a cylindrical rod running over the necessary to operate the intake and exhaust valves of the length of the cylinder bank with a number of oblong lobes cylinders. In this work, a camshaft is designed for multi protruding from it, one for each valve. The cam lobes cylinder engine and 3D-model of the camshaft is created force the valves open by pressing on the valve, or on some using modeling software pro/Engineer. The modeled in creo intermediate mechanism as they rotate. This shaft also is imported in to ANSYS. After completing the element provides the drive to the ignition system. The camshaft is properties, meshing and constraints the loads are applied on driven by the crankshaft through timing gears cams are camshaft for three different materials namely aluminium made as integral parts of the camshaft and are designed in alloy, forged steel and cast iron to determine the such a way to open and close the valves at the correct displacement, equivalent stress of the cam shaft. After taking timing and to keep them open for the necessary duration. the results of static analysis, the model analysis and A common example is the camshaft of an automobile, harmonic analysis are done one by one. which takes the rotary motion of the engine and translates it in to the reciprocating motion necessary to operate the Keywords: Finite Element Analysis, Cam Shaft, Static intake and exhaust valves of the cylinders. In this work, a Analysis, Harmonic Analysis. camshaft is designed for multi cylinder engine and 3D- model of the camshaft is created using modeling software I. INTRODUCTION pro/Engineer. The model created in pro/E is imported in A cam is a rotating or sliding piece in a mechanical to ANSYS. After completing the element properties, linkage used especially in transforming rotary motion into meshing and constraints the loads are applied on camshaft linear motion or vice versa. for three different materials namely aluminium alloy 360, forged steel and cast iron. For that condition the results have been taken has displacement values and von misses stresses for the static state of the camshaft. After taking the results of static analysis, the model analysis and harmonic analysis are done one by one. Finally, comparing the three different materials the best suitable material is selected for the construction of camshaft.

III. PROBLEM DESCRIPTION The objective of this project is to make a 3D model of the cam shaft and study the CFD and thermal behavior of the cam shaft by performing the finite element analysis.3D Copyright @ 2017 IJATIR. All rights reserved.

DR. CH. S. NAGA PRASAD modeling software (PRO-Engineer) was used for designing The cam shaft is modeled using the given specifications and analysis software (ANSYS) was used for CFD and and design formula from data book. The isometric view of thermal analysis. cam shaft is shown in below figure. The cam shaft casing body profile is sketched in sketcher and then it is revolved The methodology followed in the project is as follows: up to 3600 angle using revolve option and tubes are designed  Create a 3D model of the cam shaft assembly using and assemble to in cam shaft using extrude option. Finite parametric software pro-engineer. element analysis or FEA representing a real project as a  Convert the surface model into Para solid file and “mesh” a series of small, regularly shaped tetrahedron import the model into ANSYS to do analysis. connected elements, as shown in the above fig. And then  Perform static analysis on the cam shaft assembly for setting up and solving huge arrays of simultaneous thermal loads. equations. The finer the mesh, the more accurate the results  Perform harmonic analysis on the existing model. but more computing power is required.

IV. INTRODUCTION TO CAD/CAE Computer-aided design (CAD), also known as computer- aided design and drafting (CADD), is the use of computer technology for the process of design and design- documentation.

A. Introduction to Pro-Engineer Pro/ENGINEER Wildfire is the standard in 3D product design, featuring industry-leading productivity tools that promote best practices in design while ensuring compliance with your industry and company standards. Integrated Pro/ENGINEER CAD/CAM/CAE solutions allow you to design faster than ever, while maximizing innovation and quality to ultimately create exceptional products.

Different modules in pro/engineer: Part design, Assembly, Drawing& Sheet metal.

B. Introduction to Finite Element Method Finite Element Method (FEM) is also called as Finite Element Analysis (FEA). Finite Element Method is a basic analysis technique for resolving and substituting complicated problems by simpler ones, obtaining approximate solutions Fig2. Cam Shaft 2D Model. Finite element method being a flexible tool is used in various industries to solve several practical engineering problems. In B. Static Analysis of Cam Shaft finite element method it is feasible to generate the relative results. V. RESULTS AND DISCUSSIONS A. Models of cam shaft using pro-e wildfire 5.0

Fig1. 3D Model of Cam Shaft. Fig3. Total Deformation. International Journal of Advanced Technology and Innovative Research Volume. 09, IssueNo.05, April-2017, Pages: 0651-0654 Design and Manufacturing of a Camshaft Used in Multi Cylinder Engine

Fig7. Phase Response.

Fig4. Stress. Material Properties: Materials - forged steel Young’s modulus = 205000mpa Poisson’s ratio = 0.3 Density = 7850kg/mm3

Fig5. Strain

C. Harmonic Analysis Of Camshaft Fig8. Imported Model.

Fig6. Stress Frequency Response Fig9. Meshed Model. International Journal of Advanced Technology and Innovative Research Volume. 09, IssueNo.05, April-2017, Pages: 0651-0654

DR. CH. S. NAGA PRASAD VI. RESULTS AND DISCUSSIONS CFD Analysis Result Table: Strain Table1. Static Analysis Result Material Deformati Stress Strain 0.0035 on (mm) (N/mm2) 0.003 Forged 1.268 235.25 0.0011976 steel 0.0025 Cast iron 2.3145 240.44 0.002219 0.002 Aluminu 3.5479 227.69 0.00327 0.0015 m alloy 0.001 Strain GRAPHS: 0.0005 Deformation (mm) 0 4 3.5

3 2.5 Fig12. VII. CONCLUSION 2 The camshaft is driven by the crankshaft through timing 1.5 gears cams are made as integral parts of the camshaft and are Deformation designed in such a way to open and close the valves at the 1 (mm) correct timing and to keep them open for the necessary 0.5 duration. A common example is the camshaft of an automobile, which takes the rotary motion of the engine and 0 translates it in to the reciprocating motion necessary to operate the intake and exhaust valves of the cylinders. By observing the static analysis the stress values are less for aluminum alloy compare with forged steel and cast iron. By observing the modal analysis the deformation and frequency values are more for aluminum alloy. So it can be conclude Fig10. the aluminum alloy is better material for cam shaft.

VIII. REFERENCES [1]Machine Design by R.S. Khurmi and J.K. Gupta. Stress (N/mm2) [2] Theory of Machines by R.S. Khurmi and J.K. Gupta. 245 [3]Theory of Machines by P.L. Ballney.

240 Author's Profile: DR. CH. S. Naga Prasad received his M.Tech Degree on Heat power Refrigerator 235 and AC from JNTU, Anantapur in 2002 and Ph.D on IC Engines (Thermal Engg) from 230 JNTU, Hyderabad in 2011. He is currently Stress working as Professor & Principal in Gonna 225 (N/mm2) Institute of Information Technology and sciences, Aganampudi, Visakhapatnam, A.P, India. 220

Fig11.

International Journal of Advanced Technology and Innovative Research Volume. 09, IssueNo.05, April-2017, Pages: 0651-0654