Shop Exercise 4: Rocker Arm

OBJECTIVES:
1) TO be able to manufacture a rocker arm design using wood as material
2) to learn how to manufacture line profiles using gridlines as guide
3) To understand the principles of tapering
4) TO know the proper design elements in the manufacture of a rocker arm design.

Discussion
Rocker arms are found in automotive engines. They allow pushrods to push up
on the rocker arms which pushes down on the valves. They also change the amount of
motion transferred by a Rocker Arm Ratio. Rocker arms are used in in different kinds of
engines. They are used to allow the pushrod to push on the rocker arms which pushes into
the valves.
They are the mechanisms that allows for air and fuel intake in the engines
alternately as the engines work. With high Rocker Arm Ratio, they also multiply the motion
of each intake which then makes the engine work with more power.
When designing rocker arms, designers need to take account its geometry
because the more efficient its geometrical design, the more efficient and the more power
the rocker arm can provide. This is called Rocker Geometry or MID-LIFT Geometry and it
was coined by Jim Miller in his 1980 Patent.
The ideal leverage ratio is in the range 1:1.5:1 to 1:1.6:1. Any lower or higher
than the range of ratios would result to underperformance or faster valve guide wear
respectively. Generally, all small block Chevy's come with a 1.5:1 ratio rocker arm.

Tools/Equipment/Materials
 Stool
 Workbench/Worktable
 Backsaw
 Vernier Caliper
 Compass Saw
 Files (Rasp, Half-Round, Small, Round)
 Steel Brush
 Paint Brush
 Circle Template Ruler
 Safety Goggles
 N95 Mask
 Lab Gown
 Sandpaper (100 grit)
 Drill bit (10mm and 12mm)
  Kiln-Dried Wood (120x60x14mm)
Procedures

Mechanical Drawings

Topic Questions

1) What is a rocker arm? Explain in detail.

- Rocker arms are found in automotive engines. They allow pushrods to push up on
the rocker arms which pushes down on the valves. They also change the amount of
motion transferred by a Rocker Arm Ratio.

2) Where are rocker arms utilized? For What purpose?

- Rocker arms are used in in different kinds of engines. They are used to allow the
pushrod to push on the rocker arms which pushes into the valves. They are the
mechanisms that allows for air and fuel intake in the engines alternately as the
engines work. With high Rocker Arm Ratio, they also multiply the motion of each
 intake which then makes the engine work with more power.

3) What are the various designs of a rocker arm? Enumerate all and define each, identify
the parts and its function and provide a photo/drawing for each.

 Stamped Steel – most common type of rocker arms. They use a turn-on pivot
that holds the rocker in position with a nut that has a rounded bottom.

 Roller Tipped – similar to the stamped steel rocker arm but with an added roller
on the tip of the valve end of the rocker arm which allows for less friction and
reduced wear on the valve tip.

 Full Roller – either machined steel or aluminum, they replace the turn-on pivot
with bearings and does not use nuts. The shaft is bolted securely in place and
the bearings allow the rocker to pivot.
 Shaft Rocker Arms – they are like full roller rocker arms but with a shaft that
goes through the middle. Putting a shaft through a rocker arm provides rigidity
and provides less valve train deflection.

 Centre Pivot – looks like a normal rocker arm but the only difference is that the
Cam shaft is moved into the head and it pushes directly up on the lifter to force
the valve down.

 End Pivot (Finger Follower) – the pivot point of this rocker arm is located on the
end of the arm.
4) What is the ideal leverage ratio for a rocker arm and why so?
- The ideal leverage ratio is in the range 1:1.5:1 to 1:1.6:1. Any lower or higher than
the range of ratios would result to underperformance or faster valve guide wear
respectively. Generally, all small block Chevy's come with a 1.5:1 ratio rocker arm.

5) What materials/elements are used to make rocker arms? Define all of them and provide
an explanation why that particular material was used.
 Steel – this material is mainly used to make rocker arms for automotive
applications. This material can provide a balance between weight and durability.
 Anodized-aluminum roller rockers – made from high-quality aluminum alloy, they
have needle-bearing trunnions to allow for high valve spring loads and a tensile
strength of 80,000 psi. Great for race applications.
 High-strength alloy aluminum rocker – rockers made from this material are
lightweight performers.
 Chrome-moly steel – common material for high performance parts. It is heavier
than other materials and can provide design advantages like thinner sections.
 High-strength alloy steel – made from a superior alloy that is high in Nickel and
Chromium, it provides high yield strength to help resist deflection and resist
fatigue.

6) Why is a specific geometry required for a rocker arm design? What is it called? Who
invented it?
- When designing rocker arms, designers need to take account its geometry because
the more efficient its geometrical design, the more efficient and the more power the
rocker arm can provide. This is called Rocker Geometry or MID-LIFT Geometry and
it was coined by Jim Miller in his 1980 Patent.

7) When making shop exercise 4, what particular equipment/tool can be used to make the
rocker arm alone? State your reasons why.
- Files can be used to make the rocker arm alone because making the rocker arm
 takes precise measurements and cuts. Using files can cut excess wood to the
measurements precisely. Also, files are good for cutting around curves unlike
handsaws which is difficult to use in cutting curved surfaces.

8) What is a jig? Fixture? Why are these significant in making rocker arms?
- It is a work holding device that holds, supports and locates the workpiece and
guides the cutting tool for a specific operation. A fixture is the same as a jig, but it
does not guide a cutting tool.
These devices are important in making rocker arms because it can precisely guide
the cutting tool in making the rocker arms especially when the rocker arm has a
specific rocker geometry to follow.

9) What allowances are required to be added when making a rocker arm shop exercise 4?
provide a clear definition and measurement and the reasons for your answer.
- When making the rocker arm, it is advised to use allowances in measurements to
avoid complications in cutting in the later parts of the workshop. An allowance of 2 to
5mm is enough when cutting the wood. This is to allow improvisation and
modification so that the finish product has the exact precise measurements.

10)Where should these allowances be located on your practical work?

- These allowances should be located to all sides of the practical work.

CONCLUSION

Our group studied the proper design elements in manufacturing the rocker arm design and marked
a 10mmx10mm gridline on the workpiece before going through the practical work. With the help of
previous projects, our group was also able to understand the principles of tapering. With these all
said, our group was able to manufacture a rocker arm design using wood as material.

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