DESIGN AND ANALYSIS OF CAMSHAFT - TJPRC

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DESIGN AND ANALYSIS OF CAMSHAFT

S. S. GHODKE1 & Dr. P. R. KULKARNI2

1Research Scholar Department of Mechanical Engineering, Walchand Institute of Technology, Solapur, Maharashtra, India

2Head of Mechanical Engineering Department, Walchand Institute of Technology, Solapur, Maharashtra, India

ABSTRACT

Below expressed paper presents modeling, fatigue analysis and static structural analysis of engine camshaft. The

camshaft is one in every one of the vital components among the engines of the automobile and different vehicles.

Camshafts revolve at higher speeds which will result in the generation of vibrations in the member. In the camshafts,

as there is direct contact between cam and the plunger, a varying contact fatigue load generates. Because of these

variations, it will result in vibration and fatigue failures across the shaft. Hence, fatigue analysis must be allotted on

the camshafts to substantiate the safety and to figure out the lifetime of the member. During this thesis, for conducting

an analysis of stresses, loads & failures a finite element process employed. The ANSYS software then induced to

determine the theoretical values of stresses & loads to which camshaft member is subjected. The overall outcome of this

thesis is to design & specify camshaft theoretically, Analysing all stress, calculating theoretical stress values &

comparing it with actual once. Among the present work, we have a tendency to square measure designed Automobile

camshaft by Numerical Calculations thenceforth it's Designed by victimization Modelling software package CATIA and

CAE(Structural) Analysis is assigned in ANSYS-WORKBENCH.

KEYWORDS: Camshaft, Stress Analysis, Modal Analysis, Fatigue analysis, Finite Element Analysis & ANSYS

Received: Jun 09, 2020; Accepted: Jun 29, 2020; Published: Sep 12, 2020; Paper Id.: IJMPERDJUN20201170

INTRODUCTION

Within the Automobile sector, there is a demand for prime performance and tons of economical engines. the

camshaft is the brain of the engine. it's dominant the valve train operation and used among the engine for transfer's

motion to the body of water and valve. If the transfer of motion is not correct, then the strokes will

not add AN correct means that. Also, its effects on the performance of the engine. Among the studies on the

camshaft failures, fatigue failure sometimes initiates at stress concentrations and geometric options like holes,

grooves and corners yet due to the native property and high cycle fatigue behaviour. form of the common

development because of that the shaft failure happens contact fatigue, lean lubrication, cam plaguy and dry

wear. it's thus necessary that the fatigue analysis of the shaft administered toexamine the conditions of the

failure thus the failure avoided.

Orig

ina

l Article

International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN(P): 2249–6890; ISSN(E): 2249–8001

Vol. 10, Issue 3, Jun 2020, 12237-12248

© TJPRC Pvt. Ltd.

12238 S. S. Ghodke & Dr. P. R. Kulkarni

Impact Factor (JCC): 8.8746 SCOPUS Indexed Journal NAAS Rating: 3.11

Figure 1: Camshaft

2. MATERIAL PROPERTIES OF THE CAMSHAFT

Chemical composition shows are given in Table 2.1 that the fabric could be a Chilled forged iron. chilled forged iron is a

very important metal, giving skillfulness and low value. chilled forged iron is employed wide within the producing of

automotive components since presents sensible wear resistance, pressure tightness, sensible machinability, even at hardness

high enough to impart wonderful wear resistance, and high vibration absorption. Also, structural body chilled to spice up its

wear surface properties maintaining the among structural body merely machine prepared and decreasing the manufacturing

costs.

Table 2.1: Chemical Composition of Camshaft

C S Mn Cr ni cu Molly P su Sn

3.30to

3.80

1.5

to2.5

0.6to

1.1

0to

1%

0to

0.6% 0.to0.40%

0to

0.6%

5to

15

5

to15

0to

0.20

3. LITERATURE SURVEY

The several works of literature are reviewed related to failure analysis of camshaft assembly.

A.S. Dhavale and et.al. [1] throughout this text studied Modelling and Fracture Analysis of the shaft to vogue smart

mechanism linkages the dynamic behaviour of the parts should be thought of, this includes the mathematical behaviour of

the physical model. For this instance, the presentation of 2 mass, single level of chance and totally different level of flexibility

dynamic models of cam supporter frameworks are examined.

Bayrakceken and et.al. [2] throughout this paper they explained the fracture Associate in Nursing lysis of shaft

assembly of an automobile made-up from nodular iron. The Associate in Nursingalysed shaft is broken once an awfully short

amount of usage of the automotive. For the determination of the failure reason, the microstructure and chemical compositions

of the shaft material are determined. Some fractographic studies are applied to assess the fracture conditions. Stress analysis

is to boot applied by the finite part technique for the determination of extremely stressed regions on the shaft.

Dr P.s. Chauhan and et.al. [3] studied the finite element analysis of the camshafts assembly of assorted materials

with Different meshing conditions has been conducted within this work. SolidWorks and ANSYS Software are used for

drafting and FEA analysis of camshaft respectively.

Design and Analysis of Camshaft 12239


G. Wanga, D. Taylor and et.al.[4] throughout this paper explained Camshafts made-up from grey iron and utilised

in Rover vehicles were tested beneath cyclic bending and torsion and modelled victimisation metallic element. a

contemporary technique observed as crack modelling was acquainted with predicts the fatigue limit. The manoeuvre uses a

linear elastic finite part analysis to derive constant stress intensity issue (K) for stress concentrations in parts.

Levent Cenk Kumruog˘lu and et.al.[5] among the study, the mechanical and metallographic properties of camshafts

made from chilled iron were examined through an experiment and numerically relating with the curing, cooling rate and

metal flow. initial of all, with the assistance of the three-d drawing and magnificence programs, the overall casting

methodology was planned. This designing was analysed with casting simulation code once those camshafts were made

through an experiment at the mill.

Li Fengjun, Cai Anke and et.al.[6] throughout this paper conducted the of the fracture failure of the camshaft is that

a too sturdy chilled trend existed among the transition region. Visual section characteristic shows nearly white, the

microstructure of the fracture zone is Ledeburite, and its hardness is to boot on the far side the vary of the quality.

Mutukula Pavan Kumar and et.al.[7] among the study Modelling and analysis of camshaft is completed. Modelling

of a camshaft is completed in solid works 2016 style code. Static analysis is applied in Ansys workbench 16.0 a Load applied

is 850N and materials applied are 42CrMo4 (special alloy steel), atomic number 13 semiconducting material atomic number

12 Alloy and atomic number 12 Alloy. Structural deformations like stress, deformation and strain are studied and tabulated.

Santosh Patil, S. F. Patil and et.al.[8] During this paper studied. Camshafts revolve at higher speeds which will

result in the generation of vibrations in the member. In the camshafts, as there is direct contact between cam and the plunger,

a varying contact fatigue load generates. Because of these variations, it will result in vibration and fatigue failures across the

shaft. Hence modal and fatigue analysis need to be applied on the camshafts to form sure safety and to work out the lifetime

of the member. during this study, a numerical finite element technique was applied to on the camshaft model to carry out the

above -mentioned analysis. The camshaft was modelled in CATIA software and exported in STEP format for further analysis.

The ANSYS software was then employed, to induce the natural frequency, mode shapes and thus the fatigue alternative

stresses of the camshaft member.

S.G. Thorat, Nitesh Dubey and et.al.[9] During this article they conducted the look and analysis of the camshaft

utilizing finite part analysis. the target of the task is to set up camshaft diagnostically, it's displaying and examination beneath

FEM. In FEM, the conduct of camshaft is noninheritable by conduct the mixture conduct of the parts to influence the cam to

shaft sturdy among the smallest amount conceivable load cases.

Samta Jain and et.al.[10] During this paper studied Static Structural and Modal Analysis of Engine camshaft

victimisation ANSYS code. This paper presents a review of modelling, static structural analysis and modal analysis of engine

camshaft. the camshaft is one in all the vital elements among the engines of Associate in Nursing automobile and different

vehicles. This camshaft rotates at high speeds inflicting stress and vibrations among the system. Camshafts are subjected to

varied contact fatigue loads due to the contact of the plunger on the cam. Camshafts are rotating parts with an important load.

These actual values are required to be determined to avoid failure among the shaft.

Uma Mahesh and et.al.[11] During this paper studied the procedure geometric modelling and finite part structural

analysis of automobile camshaft among this work we tend to are designed Automobile camshaft by Numerical Calculations

thenceforth it's Designed by victimisation Modelling code CATIA and CAE(Structural) Analysis is applied in ANSYS-



WORKBENCH by varied 3 totally different materials iron, steel and ALMMC to research that material can provide the

simplest performance for camshaft.

Vivekanandan.Pa and et.al.[12] During this study they conducted Modelling, Design and Finite Element Analysis

of Camshaft. The goal of the analysis is to modelling style and analysis of a camshaft. In FEM, the behaviour of camshaft is

obtained by analysing the collective behaviour of the weather to form the camshaft sturdy among the smallest amount of

attainable load cases. This analysis may well be a vital step for fixing the optimum size of a shaft and knowing the dynamic

behaviours of the camshaft.

Wanjari and et.al.[13] throughout this paper studied the failure of the camshaft. They studied that there are 2 types

of arrangements single overhead cams and double-overhead cams. They told that in double overhead arrangement one head

has 2 cams and are typically utilised simply just in case of engines having four or additional valves per cylinder.

PROBLEM IDENTIFICATION AND OBJECTIVE

The camshaft is one of the key elements or parts within the engines of the automobile and different vehicles. Camshafts

revolve at higher speeds which will result in the generation of vibrations in the member. In the camshafts, as there is direct

contact between cam and the plunger, a varying contact fatigue load generates. Because of these variations, it will result in

vibration and fatigue failures across the shaft. modal and fatigue analysis need to be carried out on the camshafts to ensure

safety.

SHAFT DESIGN

The camshaft is one of the key elements or parts within the engines of the automobile and different vehicles. The performance

is to manage the open and shut intervals of the body of water and exhaust poppet valve valves by its cams. Due to the cyclic

impact loading on the contacting surfaces of the cam and also the follower, it typically offers rise to premature wear of cam

profile and affects a routine run of the valve gear like the movement speed, valve displacement and also the torsion. On the

opposite hand, at the same time the foremost serious, beneath cyclic bending and torsion, stress fracture of camshaft initiating

at stress concentration simply happens. Therefore, it demands the shaft has not solely wonderful wear resistance however

conjointly adequate anti-impact toughness.

The camshaft was thought of as a merely supported beam with cams replaced by their equivalent forces performing

on the shaft. The free-body diagram of the camshaft with the forces performing on its presented in Figure 2.

Given Data : Speed = 2000 rpm

Torque = 150 Nm

Min. Shaft dia = 28 mm

Force on each cam lobe = 1200 N

Permissible stress calculation :

From material property :

Syt = 380 Mpa

Sut= 650 Mpa



From ASME code for shaft design :

τmax = 0.3 Syt

= 0.3 x 380 = 114 N/mm2

τmax = 0.18 Sut

= 0.18 x 650 = 117 N/mm2

Thus lower of two is 114, hence

τmax = 114 N/mm2

Actual Stress Calculation

The camshaft was thought of as a merely supported beam with cams replaced by their equivalent forces performing on the

shaft. The free-body diagram of the camshaft with the forces performing on its presented in Figure2.

Figure 2: Free Body Diagram of the Camshaft

Bending moment at A = 160X1200 = 192000 Nmm

Bending moment at B = 160X1200 = 192000 Nmm

Bending moment at C = 145X1200 = 174000 Nmm

Thus maximum B.M. on shaft is 192000 Nmm

Mb = 192000 Nmm

Similarly, Torque,

MT = 150000 Nmm

τmax =16

πd3 √(KbMb)2 + (KtMt)2 ------------------------------(1)

From ASME code Kb = 1.5 and Kt = 1

Considering permissible stresses in shaft as

τmax = 114 N/mm2 the shaft diameter comes to be Shaft dia d = 24.38 ~ 25 mm

Whereas minimum diameter on camshaft is 28 mm hence shaft is safe for diameter size.



Let’s calculate the stresses developed in the camshaft due to the given loading conditions

τa =16

π(28)3√(1.5 x 192000)2 + (1 x 150000)2

τa = 75.33 N/mm2

Thus the generated stress is less than permissible stress, hence shaft is safe for failure.

DESIGN SPECIFICATIONS AND INPUTS

Table 6.1: Design Specifications and Inputs

No Design Specification Value

1 RPM of the camshaft 2000rpm

2 Torque of the drive shaft 150Nm

3 Min Shaft diameter 28mm

4 Force on each lobe 1200N

5 Length of camshaft 420mm

6 Weight of cam lobe 100N

FAILURE DETAILS

Some of the common phenomena because of that the camshaft failure happens square measure contact fatigue, depleted

lubrication, cam pestering and dry wear. it's so vital that the fatigue analysis of the camshaft ought to be distributed. It’ll

confirm the conditions of the failure so the failure is avoided.

One of the lot of common causes of shaft failure is because of fatigue. Metal fatigue is caused by continual athletics

of the load. it's a progressive localized injury because of unsteady stresses and strains on the fabric. Metal fatigue cracks

initiate and propagate in regions wherever the strain is most sever. The thought of fatigue is extremely easy once motion is

continual the article that's doing the work becomes weak. Fatigue happens once a fabric is subject to alternating stresses,

over an extended amount of your time.

FAILURE LOCATION

Fatigue can be is classified by the shape within which it occurs: mechanical, creep, thermomechanical, corrosion, rolling

contact, and fretting fatigue. Fatigue may be classified by the period of the fatigue life: low-cycle and high-cycle fatigue

failure in elements typically initiate at stress concentrations: geometric options like holes, grooves and corners, and despite

some native malleability, high-cycle fatigue behaviour is actually a linear elastic drawback.

FATIGUE FAILURE ANALYSIS OF CAMSHAFT

Some of the common phenomena because of that the camshaft failure happens square measure contact fatigue, depleted

lubrication, cam pestering and dry wear. it's so vital that the fatigue analysis of the camshaft ought to be distributed. It’ll

confirm the conditions of the failure so the failure is avoided.

In the fatigue analysis the camshaft is modelled similar as that of static analysis. In the static structural analysis, one

of the end of camshaft is given moment / torque of 150 Nm and also rotational speed of 2000 rpm. The direction of both

moment and rotational speed are defined in the same direction. With all other similar boundary conditions as that of static

structural analysis, the model is solved.



Figure 3: Alternating Stress Camshaft- fatigue chamfer 1.5

Figure 4: FOS of camshaft – fatigue chamfer 1.5

The alternating stress found out in the camshaft is 83.026 Mpa and factor of safety was found to be minimum 1.038.

This alternating stress developed in the camshaft is slightly more than the equivalent stress in the camshaft. Hence camshaft

is prone to fail near the corners of cams i.e. at chamfer area.

To eliminate the chances of failure, the chamfer size of camshaft is increased. The previous chamfer size was 1.5

mm; and this size is changed and increased by 0.5 mm. The new chamfer size is 2.0 mm. Now the modified camshaft model

is solved with all boundary conditions and loading conditions same as that of previous and results are extracted.



Figure 5: Alternating Stress Camshaft- fatigue chamfer 2.0

Figure 6: FOS of camshaft – fatigue chamfer 2.0

In the modified results, the alternating stress is 65.83 Mpa and the factor of safety is minimum 1.31. Thus the stress

result and factor of safety both are improved in the second result i.e. for increased chamfer size.

RESULTS

Table 9.1: Fatigue Failure Analysis of Camshaft Results

Equivalent stress Alternating stress FOS

Fatigue chamfer1.5 75.33 83.026 1.038

Fatigue chamfer2.0 75.33 65.83 1.31

MODELLING OF CAMSHAFT

Modelling may be a pre-processor tool, the modelling of the camshaft is formed victimization the Computer-aided three-

dimensional interactive application (CATIA) V5 R20 code tool. half and form style square measure the essential modules of

style in CATIA code. they're supported many tools for straightforward and qualitative modelling of any quite machine parts.

The primary step of style any half is to outline position (plane) of Sketch and to draw the profile in chosen Sketch.



Figure 7: Modelling of Camshaft

STATIC ANALYSIS OF CAMSHAFT

Model:

Meshing



Boundary Conditions

Stress :

Strain



Total Deformation

RESULTS

Table11.1: Static Structural Results

Material Max stress Total deformation Max strain

Chilled cast iron 65.832 0.18463 0.00033395

CONCLUSIONS

The camshaft is one amongst the key elements or parts inside the engines of the car and completely different

vehicles. There are varied factors that cause the failure of the camshaft. Fatigue analysis needs to be carried out on

the camshafts to ensure safety.

Determination Theoretical Calculation for Equivalent Stress of camshaft. The alternating stress calculated

victimization ANSYS module. ANSYS stress values square measure conventionally then compared with the

theoretical stress values. This alternating stress 83.026 Mpa developed in the camshaft is slightly more than the

equivalent stress in the camshaft. Hence camshaft is prone to fail near the corners of cams i.e. at chamfer area. To

eliminate the chances of failure, the chamfer size of the camshaft is increased. The previous chamfer size was 1.5

mm, and this size is changed and increased by 0.5 mm.

In the modified results, the alternating stress is 65.83 Mpa and the factor of safety is minimum 1.31. Thus the stress

result and factor of safety both are improved in the second result i.e. for increased chamfer size. Static analysis is

carried out in ANSYS workbench. Structural deformations like stress, deformation and strain square measure

studied and tabulated.

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pp. 1240-1245

3. Dr. P.S. Chahuan and Juber Hussain,2018, Finite Element Analysis of NCI, GCI, AND EN 18 Materials Camshaft, European

Journal of Mechanical Engineering Research Vol.5, No.2, pp.24-34, May 2018

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SINGLE CYLINDER DIESEL ENGINE TO REDUCE NOISE AND VIBRATION." International Journal of Mechanical and

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