EXPERIMENTAL ANALYSIS OF CAM ROLLER OF INTERNAL COMBUSTION ENGINE BY CHANGE IN AREA OF CONTACT

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp. 99-105© IAEME

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EXPERIMENTAL ANALYSIS OF CAM ROLLER OF

INTERNAL COMBUSTION ENGINE BY CHANGE IN

AREA OF CONTACT

Prof. L. B. Raut. Guide& (M.E Co-ordinator) 1, Akkamahadevi G. Chanagond (Kalyankar) 2

1,2

SVERI’S, college of Engineering, Pandharpur

ABSTRACT

Most of the IC engines used in the market have roller cam and follower mechanisms, having a line contact between the cam and the roller follower. In a effort to improve the mechanical efficiency of the mechanism the company requires us to change the line contact to a point contact. Hence it is required to change the flat roller follower to a curved profile. The existing cam & follower mechanisms used in Internal Combustion engines have a line contact between them causing frictional losses. These frictional losses in present line contact are being considered on the higher side. These frictional losses affect the total efficiency of an Internal Combustion engine. The mechanical efficiency of cam & follower mechanism is to be increase by minimising the frictional losses.The roller of rocker arm of a Hero Honda passion bike is replaced by new one to check performance experimentally.

Keywords: Cam; Follower; Line contact; Point Contact; Vibration Analysis;

I. INTRODUCTION

In the 21th century, with the advance technologies the various vehicles have been modified as per the requirement of a consumer. Sometimes there is modified ignition system, modified shape, different cylinder arrangements etc. Thus we have decided to change the shape of a roller. The roller of the cam follower mechanism is of flat type; which makes line contact with cam. This line contact of roller with cam will be changed to point contact by doing modification in the geometry of a roller. The modified geometry of a roller should satisfy conditions:

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ISSN 0976 – 6340 (Print) ISSN 0976 – 6359 (Online)

Volume 6, Issue 2, February (2015), pp. 99-105

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1. It should make point contact with cam of cam-follower mechanism.

2. The values of stresses of an original geometry and modified geometry should be within limit. 3. The value of frequencies of an original geometry and modified geometry should be within range.

The dimensions required for roller is measured manually by using vernier caliper in the workshop of a college as shown in figure 1 below. Another data required for analysis of a roller is given by a company as shown in the table 1 below.

Fig: 1. Details of Rocker Arm, cam roller

Table: 1 Properties 1 Material 100cr6 2 Young's modulus 2.1e5MPas 3 Poisson Ratio 0.3

4 Density 7.850×10-6 Kg/mm3 5 Yield Strength 410MPa

II. TEST CRITERIA

1. Roller dimensions of Old Line & New Point contact roller

Width =8.1mm Width =8.1mm

Fig 2. Dimension of old and New Roller

Outer Dia. 18.24 mm Inner Dia. 12.17 mm Dia. 12.17 mm

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Total 4 tests are conducted on motorcycle engine (Hero Honda passion) with replaced Stainless tungsten chrome steel roller –(N8) which is case hardened & with old roller also.

Test 1: Measurement of vibration parameters with old line contact roller.

Test 2: Measurement of Noise with old line contact roller.

Test 3: Measurement of vibration parameters with new modified point contact roller.

Test 4: Measurement of noise with new modified point contact roller.

2. Experimental set up of vibration parameters with old line contact and new modified contact roller

Fig 2: Measurement of vibration parameters with old line and new modified contact roller

Above shows close up of accelerometer attached magnetically to the engine that vibration test is going on with the accelerometer sensor held in hand further stuck to engine body I C engine of Hero Honda passion motor cycle. These readings are stored in FFT analyzer shown and later on analysed in SWAN TECH software given by FFT supplier to produce graphs.

3. Experimental set up of noise with old line and new modified point contact roller

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp.

Above (Photo) shows that noise test is going on with the noise sensor probe held in hand at the approximately same distance for all four sides of I C engine of hero Honda passion motorcycle to get a average reading. These tests are taken for old and new roller t

These readings are stored in FFT analyser and later on analysed in mat lab to produce graphs

III. RESULT AND DISCUSSION

1. TIME DOMAIN ANALYSIS

Graph 1:

Above Graph shows Maximum amplitude is

to be reduced. Time span is taken 15 seconds for every reading.

2. TIME DOMAIN ANALYSIS roller)

Graph 2:

Above Graph shows maximum amplitude is

reduced. Time span is taken 15 seconds for every reading. In old roller it was

our optimization is successful. The amplitude level decreases considerably by new roller. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976

6359(Online), Volume 6, Issue 2, February (2015), pp. 99-105© IAEME

102

(Photo) shows that noise test is going on with the noise sensor probe held in hand at the approximately same distance for all four sides of I C engine of hero Honda passion motorcycle to get a average reading. These tests are taken for old and new roller that is line and point contact type. These readings are stored in FFT analyser and later on analysed in mat lab to produce graphs

RESULT AND DISCUSSION

ANALYSIS OF VIBRATION SIGNAL (with old line contact roller)

Graph 1: Time domain Analysis of vibration signal

shows Maximum amplitude is 11mm shown in graph which is very high need to be reduced. Time span is taken 15 seconds for every reading.

ANALYSIS OF VIBRATION SIGNAL (with new modified point contact

2: Time domain Analysis of vibration signal

shows maximum amplitude is 3mm shown in graph which is very low i.e. reduced. Time span is taken 15 seconds for every reading. In old roller it was 11 mm

The amplitude level decreases considerably by new roller.

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), © IAEME

(Photo) shows that noise test is going on with the noise sensor probe held in hand at the approximately same distance for all four sides of I C engine of hero Honda passion motorcycle to hat is line and point contact type. These readings are stored in FFT analyser and later on analysed in mat lab to produce graphs.

OF VIBRATION SIGNAL (with old line contact roller)

shown in graph which is very high need

with new modified point contact

shown in graph which is very low i.e.

11 mm so high. Hence The amplitude level decreases considerably by new roller.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp.

3. TIME DOMAIN ANALYSIS OF ACOUSTIC (NOISE) signal old

Graph 3: Time domain Analysis of acoustic (noise) signal

Above Graph shows Maximum amplitude is

need to be reduced. Time span is taken 15 seconds for every reading.

4. TIME DOMAIN ANALYSIS OF ACOUSTIC (NOISE) signal New

Graph 4: Time domain Analysis of acoustic (noise) signal

Above Graph shows Maximum amplitude is Time span is taken 15 seconds for every reading. optimized roller. Hence our optimization is successful. by new roller.

5. Vibration spectral analysis

Comparison of effect on amplitude & frequency by both rollers

Shows the vibration spectrum of old roller at idling speed of motorcycle (pink line) and modified point contact roller (black line)

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6359(Online), Volume 6, Issue 2, February (2015), pp. 99-105© IAEME

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S OF ACOUSTIC (NOISE) signal old roller

Time domain Analysis of acoustic (noise) signal

shows Maximum amplitude is 50000 DB shown in graph which is very high need to be reduced. Time span is taken 15 seconds for every reading.

S OF ACOUSTIC (NOISE) signal New roller

Maximum amplitude is 45000 DB shown in graph which is reduced. Time span is taken 15 seconds for every reading. The amplitude level decreases considerably by new

Hence our optimization is successful. The amplitude level decreases consider

Vibration spectral analysis

Comparison of effect on amplitude & frequency by both rollers with old line contact roller Shows the vibration spectrum of old roller at idling speed of motorcycle (pink line) and

contact roller (black line)

roller

shown in graph which is very high

roller

shown in graph which is reduced. The amplitude level decreases considerably by new The amplitude level decreases considerably

with old line contact roller. Shows the vibration spectrum of old roller at idling speed of motorcycle (pink line) and with new

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Graph 5: Comparison of effect on amplitude & frequency by both rollers

6. RMS VALUE

IV. CONCLUSION

The change of roller can significantly reduce the costs of maintenance. In this research, vibration and acoustic signals were used in an engine of motorcycle. It was shown that various types of signals can be detected successfully by both types of rollers by acoustic and vibration signals analysis. The acoustic analysis method has gained wide industrial acceptance for engine condition monitoring. In this dissertation, shows the considerable freedom in positioning of the microphones - distance and plane with respect to the source, and being able to detect the characteristic frequency spectrum of the engine and consequently diagnosis using advanced signal processing. In this dissertation work, experimentation is carried out to vibration & noise level difference through acoustic and vibration analysis and feasibility of practical application of new modified roller in engine of motorcycle is investigated. The acoustic and vibration spectrums obtained for different rollers are presented on which following conclusions can be drawn.

1. Using Frequency Domain Spectrums

With new point contact roller & old line contact roller a comparison shown that it reflects the change in spectrum. It is observed from the amplitude of frequency has decreased considerably.

2. Using Time Domain Spectrums

With comparison of time domain spectrum, it is observed that an RMS value was decreased by the use of new point contact roller in engine of motorcycle.

New roller Old roller VIBRATION 0.9331 1.0233

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