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AEROSPACE COATINGS LTD

CAMSHAFT AND TAPPET


TEST RIG

PRESENTATION SUMMARY

Introduction
Overview of the Camshaft and Tappet
system.
Load conditions and environment
Failure and wear
The Rig
Conclusions

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OVERHEAD CAMSHAFT
WITH INVERTED BUCKET
FOLLOWER

Overhead camshaft
with inverted bucket
follower is the
configuration type
selected for our Test
Rig
Camshaft acts directly
onto the tappet and
directly actuates the
valve
Stone, R, Introduction To Internal
Combustion Engines [1]
AEROSPACE COATINGS LTD

CAMSHAFT LOBE FEATURES

The Camshaft lobe has three


main features
1)
Ramp
2)
Flank
3)
Nose
What are their
characteristics?
Acceleration
Valve lift proportional to
lobe radius
Zero velocity at maximum
lift (turning point)
Heisler, H, Advanced Engine Technology
[2]
AEROSPACE COATINGS LTD

LOAD CONDITIONS AND


ENVIRONMENT

Diagram shows the force at


the tappet with respect to
camshaft angle

The three curves


represent different
engine speeds

Maximum force is not


necessarily at maximum
valve lift.
Inertial force overcomes
spring force due to
increased acceleration

Stone, R, Introduction To Internal Combustion


Engines[1]

AEROSPACE COATINGS LTD

FATIGUE FAILURE (PITTING)

Fatigue accounts for


90% of failure in metals
Biggest culprit of
camshaft failure.
Cracks propagate
under the surface due
to shear stresses.
Correct materials
selection and
processes can prevent
this.

Pitting and spalling on a cam lobe (above) and


tappet (below)

www.tribology-abc.com [3]

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FAILURE ANALYSIS

Microscopy images

X 50 Mag

X 50 Mag

Top image shows


formation of fatigue
cracks and broken off
material
Bottom image shows
loss of material due to
fatigue, combined with
abrasive wear.

These images show camshaft


surface fatigue and abrasive
failure.
The cause of this is due to a
build-up of Hertzian stresses
under the surface.
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THE DESIGN
Torque
transducer

Drive pulley

Test bed

To be situated
on trolley:
Motor
Clutch
Oil pump
Plummer block

Camshaft

Sump
Heater
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DESIGN FEATURES

Simulated valve mass.

Adjustment for valve spring


compression.

Probe type displacement


sensor attached to rod.

Section through tappet and


housing

Shims to allow for


larger or smaller
springs
Dual spring retainers

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DESIGN FEATURES
Shims allow for
tappet rotation
Oil grooves on tappet

Tappet configuration
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CYLINDER HEAD TEST RIG


Fiat 1.9 JTD engine in place on the cylinder
head test rig.

AEROSPACE COATINGS LTD

CONCLUSIONS

The use of a Camshaft and Tappet test rig is highly


beneficial

Results can be applied to all aspect of material


testing.

Simulates dynamic environments

Excellent example of a harsh tribological environment

Fatigue testing
Cost and time effective

Easy to analyse, prepare and set-up

AEROSPACE COATINGS LTD

REFERENCES
[1] Stone, R Introduction to Internal Combustion Engines, The
Macmillan Press, 2nd Edition 1992, ISBN 0-333-55083-6
[2] Heisler, H - Advanced Engine Technology, Butterworth-Heinemann,
1st Edition 2002, ISBN 0-340-56822-4
[3] http://www.tribology-abc.com/poll/case03.htm-accessed 2/12/04
[4] http://www.hbm.com/products/ - accessed 1/04/05

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