Design of Mechanical Elements

ME 3035
Project Report, Spring 2013

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Objective: To apply method of analysis of mechanics, machine design and strength
of materials to a proposed case study.

Case study: Analysis of a camshaft-valve system of a 6.5 HP gas engine and pump,
Pacific Hydrostar Water Pump (Figure 1).

Figure 1: Hydrostar Pump motor






















Section A.

A. An Ability to apply knowledge of mathematics, science and
engineering.

Application of Math and science on the analysis of the main parts of a manual
clutch.

A.1. System Functions

Case Study: Analysis of camshaft- valve system of a 6.5 HP gas engine and pump

Engine:
4-stroke
one cylinder
Spark Ignition
internal combustion engine
Important design characteristics:
o Used for light weight applications
o Small bulk
o Low cost compared to power generated
Less important design considerations:
o Fuel Consumption
o Engine vibration
o Engine durability
One power stroke for every 2 revolutions
Torque pulses are widely spaced causing significant vibration and
smoothness problems.
Naturally aspirated
Air cooled
Max power is 6.5 HP at 3200 RPM
Recoil start
Overhead Valve
Spark-Ignition Engine Operation:

Air and fuel are mixed prior to combustion.
Ratio of mass flow of to mass flow of fuel must be approximately 15 to
ensure proper combustion.
Four stroke:
o Intake stroke: brings fresh air fuel mixture into the cylinder.
Intake valve opens before stroke and closes after it ends to
increase mass inducted.
o Compression stroke: With both valves are closed; the fuel air
mix is compressed to a small fraction of starting volume. Near
the end of the stroke, combustion is started by a spark from the
spark plug. Pressure in cylinder is raised rapidly at this point.
o Power stroke: (expansion) High temperature/high pressure
gasses force the piston down and cause the crankshaft to
rotate. Almost 5 times the amount of work is done on the
piston during the power stroke compared to the work the
piston had to do during the compression stroke. The rotation
of the crankshaft is used to control the other parts within the
motor.
o Exhaust stroke: Burned gases exit the cylinder through the
exhaust valve. This is due to the cylinder pressure is much
higher the pressure in the exhaust system.




Valve Spring Functions:
Valve springs in the combustion motor are very important in
controlling the breathing of the motor. A camshaft with lifters and
pushrods mechanically opens the valves by the vale springs. The valve
springs lift the weight of the valve;
Overcoming friction on the valve shaft when the valve closes Creating
enough friction, or drag, to keep the valve train and valve following
the camshaft profile accurately, by always providing (slightly) greater
force than the inertial force of the accelerated mass of the valve. At the
same time, the valve-spring forces must not be so large as to create
excessive friction on the cam and potential loss of performance.

Push Rods Functions:

A push rod is defined as a metal rod transmitting the reciprocating
motion that operates the valves of an internal-combustion engine
having the camshaft in the crankcase. This piece is an integral part of
an overhead valve system in an internal combustion engine. This
piece is operated by both the rocker and the crankshaft. As the crank
shaft is spinning it comes in contact with the lifter the cam on the
crankshaft pushes on the lifter engaging the pushrod which in turn
exerts a force onto the rocker arm. The pushrod engine was first seen
in 1949 with the Oldsmobile rocket v8 and since has been a reliable
cost effective alternative to belt or chain driven motors.

Valve Functions:
Valves can be seen in all combustion engines it is possibly one of the
most important components of the engine. A valve is generally a
circular tapered piece of highly resistant metal, this is because the
valves regulate the intake and exhaust within an engine. Within a four
stroke engine there are two values which are precisely timed with the
cams and or crankshaft of the engine. First the intake valve is opened
allowing air/fuel mix to enter the cylinder it is then compressed and
ignited then the exhaust valve is opened and the waste from the
combustion process is removed from the cylinder. These functions
happen at extreme rates so it is very important to have a high strength
valve. (www.eibach.com)



A.2. Analysis of the cam profile

Camshaft and Cams:
Camshaft is made of cast iron or forged steel
One cam per valve is used to open and close the valves
Four stroke engine camshafts turn at one-half the crankshaft speed
Cam surfaces are hardened to extend life
Camshafts are gear, belt or chain driven from the crankshaft
Additional members may be required to transmit motion to the valve stem


A.3. Analysis of the springs



A.4. Analysis of the pushrods

Pushrods can be made out of various types of metals and even ceramics but
have to deal with intense stress and heat. The most common material for
engine pushrods is high carbon steel but these typically cannot withstand
high rpm and higher temperatures. That is why the use of other materials can
typically be found in performance vehicles, such as aluminum, titanium,
Aluminum Matrix Composites, and even epoxy resin graphite combination.
Failure in pushrods can be accounted in excessive surface roughness
between the pushrod and the rocker arm. Another failure can occur if a high
load is applied and the material buckles reducing its effective length then
impeding the distance the valve will open.

A.6. Analysis of the valves.

Valves are typically made from forged allow steel other materials are nickel,
tungsten and titanium. These valves operate at high heat around 700 degrees
Celsius and are sometimes filled with sodium, which evaporates and
condenses to carry heat from the valve head. The valves may also be coated
in a heat resistant coating of aluminum or iron aluminum alloy. Typical
failures with in valves are caused by imperfections in the valves that lead to
deformation or fracture. High engine temperatures in the engine can lead to
heat stress brakeage of the exhaust valve. Improper timing in the engine will
lead to valve bending or fracture.


A.7. Analysis of the vibration system

Others ???

Section B.

B. An ability to design and conduct experiments, as well as to analyze
and interpret data

B.1. Design of a set-up to experimentally determine the spring constant, and
other properties of the helicoidal spring. Compare the theoretical and
experimental data.

B.2. Design of a set-up to experimentally determine the mechanical
properties of fasteners (HEAD BOLTS) such as torque, deflection and
stiffness ratio, etc.

B.3. Experimental determination of the bucking load for equaling push rod
pins

Section C.

C. An ability to design a system, component, or process to meet desired
needs.

C.1. Estimate of the maximum pressure based on the P-V diagram.

C.2. Calculate the forces and deflection acting on the camshaft

Section D.

D. An ability to function on multi-disciplinary teams.

D.1. Planning
D.2. Organization
D.3. Distribution of the work
D.4. Coordination

Section E.

E. An ability to identify, formulate, and solve engineering problems

E.1. Analysis based in proper assumptions
E.2. Physics and Mathematical formulation
E.3. Consistent with assumptions

Section F.

F. An understanding of professional and ethical responsibility

F.1. Late work by team members
F.2. Professional attitude towards meetings
F.3. Lack of individuality of the work

Section G.

G. An ability to communicate effectively

G.1. Written explanation and descriptions
G.2. Quality of project report

Section H.

H. The board education necessary to understand the impact of
engineering solution in a global and societal context

Section I.

I. A recognition of the need for, and an ability to engage in life-long
learning

Section J.

J. A knowledge of contemporary Issues

Section K.

K. An ability to use the techniques, skills, and modern engineering tools
necessary for engineering practice

K.1. Use of a 3-D modeler (SolidWorks)
K.2. Use of a Word Processing (MS Word)
K.3. Use of measurements instruments
K.4. Others ???