Modeling of CAM Shaft ( 4stroke Petrol Engine) Using

CATIA V5
In partial fulfillment of the requirements for the degree of

Bachelor of Technology

In

Mechanical Engineering

Submitted By

Y.Sai Sumanth, AVN Sri Harsha, R.Vamsi

(17B81A03J2,17B81A03M2, 17B81A03M7)

Department of Mechanical Engineering

CVR COLLEGE OF ENGINEERING

(UGC Autonomous Institution)

Affiliated to JNTU Hyderabad

Vastunagar, Mangalpalli (V), Ibrahimpatnam
(M),Ranga Reddy (Dist.), Hyderabad – 501510,
Telangana State
(2020-2021)
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 CVR COLLEGE OF ENGINEERING
(UGC Autonomous Institution)
Affiliated to JNTU Hyderabad
Vastunagar, Mangalpalli (V), Ibrahimpatnam (M),
Ranga Reddy (Dist.), Hyderabad – 501510, Telangana State

CERTIFICATE
This is to certify that the industry oriented mini-project work topic entitled

‘Modeling of CAM Shaft using CATIA V5’ being submitted by ‘Y.Sai

Sumanth(17B81A03J2),AVN Sri Harsha(17B81A03M2),R.Vamsi(17B81A03M7)’

for partial fulfillment of the requirement for the award of ‘Bachelor of

Technology in Mechanical Engineering discipline.

Mini Project Supervisor Head of the Department

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 CVR COLLEGE OF ENGINEERING
(UGC Autonomous Institution)
Affiliated to JNTU Hyderabad
Vastunagar, Mangalpalli (V), Ibrahimpatnam (M),
Ranga Reddy (Dist.), Hyderabad – 501510, Telangana State

DECLARATION

We “Y.Sai Sumanth, AVN Sri Harsha, R.Vamsi” are student of IV B.Tech I Sem in Mechanical
Engineering, CVR College of Engineering, Hyderabad, Telangana State, hereby declare that the
industry oriented mini-project work presented in this report titled “ Modeling of CAM Shaft
Using CATIA V5” is the outcome of our bona fide work and is correct to the best of our
knowledge and this work has been completed with taking care of engineering ethics .

Date:

Y.Sai Sumanth 17B81A03J2

A.V.N. Sri Harsha 17B81A03M2

R. Vamsi 17B81A03M7

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 ACKNOWLEDGEMENT

We are greatly indebted to Mr. Neeraj Kumar Jha, (Assoc.Prof) my revered guide
for his valuable affectionate guidance in the preparation of this project work.
He has been a source of great inspiration and encouragement to us. He has
been kind enough to devote considerable amount of his valuable time in
guiding us at every stage. This is our debut, but we are sure that we will be able
to do many more such studies, purely because of his lasting inspiration and
guidance. We are highly grateful to him for helping us with necessary
information and material. He has not only guided but also endowed us with
capacity to guide us in future.

We would like to express heart full thanks to Dr. M. Venkata Ramana,

Professor and Head of the Department of Mechanical Engineering, who have
always been grateful for us to complete our project.

We would like to express heart full thanks to Dr.S.Nayanathara,

Principal, who have always been grateful for us to complete our project
“Modeling Of CAM Shaft Using CATIA V5”.

We also thank all the teaching and non – teaching staff members of
Department of Mechanical Engineering who have helped us directly or
indirectly during the project.

Y.Sai Sumanth 17B81A03J2

AVN Sri Harsha 17B81A03M2
R.Vamsi 17B81A03M7

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 ABSTRACT

A Shaft With One Or More Cams Attached To It, Eg . Working Of Values In An

Internal Combustion Engine Is Controlled By Cam Shaft. Cam Shaft Is Called
The “BRAIN” Of The Engine.

A Projection On A Rotating Part In Machinery, Designed To Make Sliding

Contact With Another Part While Rotating And To Impact Reciprocal Or
Variable Motion To It. Cams Are Used To Convert Rotary Motion Into
Reciprocating Motion.

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Table Of Contents:

1. Introduction………………………………………8

2. Image Of The Model………………………………………….10

3. Steps To Be Followed For Modeling……………………11

4. Materials Of The Component……………………………..12

5. Manufacturing Methods Of The Component…….13

6. Applications Of The Component………………………..14

7. Conclusion…………………………………………………………16

8. Future Scope……………………………………………………..17

9. References………………………………………………………...18

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Introduction:

A camshaft is a shaft to which a cam is fastened or of which a cam forms an integral part within
an internal combustion engine a camshaft is a long slender rod that has several individual cam
lobes attached to it .these lobes are responsible for pushing against valves that open and close
the exhaust stroke and compression strokes.

CAM TERMINOLOGY

Base Circle: The smallest circle centered on the cam rotation axis, and tangent to the cam
surface. The size of the base circle is dictated by spatial restrictions of the application.

Trace point: A theoretical point on the follower, corresponding to the point of a fictitious knife-
edge follower. It is used to generate the pitch curve. In the case of a roller follower, the trace
point is at the center of the roller.

Home Position: The orientation of the cam that corresponds to 0° on a displacement curve.

Reference Circle (or prime circle): A circle centered at the cam axis whose radius is equal to the
distance to the trace point. It is the smallest circle from the cam center through the pitch curve

Pressure Angle: The angle between the direction of motion of the follower and the direction of
the cam contact force is called pressure angle. Pressure angle should not exceed 30°.

Pitch curve: The path generated by the trace point at the follower is rotated about a stationary
cam.

Working curve : The working surface of a cam in contact with the follower. For the knife-edge
follower of the plate cam, the pitch curve and the working curves coincide. In a close or
grooved cam there is an inner profile and an outer working curve.
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 CAM SHAPE
1. PLATE CAM OR DISC CAM:
The follower moves in a plane perpendicular to the axis of rotation of the camshaft. A
translating or a swing arm follower must be constrained to maintain contact with the cam
profile.
2. GROOVED CAM or closed cam:
This is a plate cam with the follower riding in a groove in the face of the cam.

MOTION OF THE CAM

When the cam turns through one motion cycle, the follower executes a series of events
consisting of rises, dwells and returns. Rise is the motion of the follower away from the cam
center, dwell is the motion during which the follower is at rest; and return is the motion of the
follower toward the cam center.

Lift:
> Lobe lift is the distance the lifter moves in one direction.
> Lobe lift is the difference in measurement between the nose of the lobe and the base
circle of the lobe.
> Valve lift is what most people are taking about when they refer to lift and is simply lobe lift
multiplied by the rocker arm ratio.

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IMAGE OF THE MODEL:

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PROCEDURE:

1. Installing the software

> create an auto desk account

>install CATIA V5 software

3. Basic Orientation

> set up workspace

> change units in CATIA V5
> Explanation of the workspace

4. 2D Sketches

>setup snapping
>Drawing a line
> select an object
> Drawing tools

5. Modeling 3D Shapes

>3D build basic shapes

> Merge , subtract and intersect 3D objects
> Sweep, loft and revolve feature

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MATERIALS USED IN CAMSHAFT:
Camshaft material is the most important detail in stopping premature wear of performance
camshafts.
There are various materials that camshafts are manufactured from:-

CAST IRONS

1. HARDENABLE IRON:
This is Grade 17 cast iron with an addition of 1% chrome to create 5 to 7% free carbide.
After casting, the material is flame/or induction hardened, to give a Rockwell hardness of 52 to
56 on the C Scale. It is not the most suitable material for performance camshafts in overhead
cam (OHC) engines.

2. SPHEROIDAL GRAPHITE CAST IRON KNOWN AS SG IRON:

A material giving similar characteristics to hardenable Its failing as a cam shaft material is
hardness in its cast form, which tends to scuff bearings in adverse conditions. The material will
heat treat to 52 to 58 Rockwell C. This material was used by Fiat in the 1980’s

3. CHILLED CHROME CAST IRON:

Chilled iron is Grade 17 cast iron with 1% chrome. When the camshaft is cast in the foundry,
machined steel moulds the shape of the cam lobe are incorporated in the mould. When the
iron is poured, it hardens off very quickly (known as chilling), causing the cam lobe material to
form a matrix of carbide (this material will cut glass) on the cam lobe. This material is
exceedingly scuff-resistant and is the only material for producing quantity OHC performance
camshafts.

STEEL CAMSHAFTS

1. CARBON STEEL – EN8 (BS970 080M40) /EN99 (BS970 070M55):

Used mainly in the 1930 to 1945 period and is currently used for induction hardened camshafts
in conjunction with roller cam followers, due to the through-hardening characteristics of the
material.

2. ALLOYED STEELS – EN351 AISI 8620 and EN34:

Used by British Leyland in the A Series and B Series engine and best when run against a chilled
cam follower.

3. NITRIDING STEEL – EN40B:

The best steel for camshafts. When nitrided it gives a surface hardness and finish similar to
chilled iron. We used this when replacing chilled iron camshafts in competition engines. This
material is used on several of the current F1 engines.

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METHODS OF MANUFACTURING:
1. CASTING:
Chilled cast iron is primarily used for production of cam shaft. The development of automobile
industry and engine power brings up more advance requirement for properties of camshaft. In
casting process, there are more chances of casting defects such as shrinkage defect, porosity,
crack, insufficient pouring. However for higher loads in roller contact, cast camshafts with
induction hardened cam lobes can be used.

2. FORGING:

Forged or manufactured from a steel bar camshafts are also used for certain high loaded diesel
engines. These are produced on computer-controlled forging systems with integrated heat
treatment or machined from steel bar.

3. MACHINING: Machining is necessary for giving final dimension to the cam.

A. While using Casted or Forged CAM only Final Machining is require to achieve final size within the
required tolerances. In this process casted or forged CAM are in the required shape but their
size is maintained by machining and finishing operation.

B. While Using Metal Billet (metal rod), the profile of cam is obtained by removing excess material
which from metal billet. In this process only machining is required to manufacture CAM.

A detailed description of the processes for mass manufacturing is as follows:

1 .TURNING & DRILLING: The raw forging is put in this machine and center drilling and turning on one side is done
here.

2. TURNING: Here the turning of the 6 journals takes place. There are 4 tools used for this turning – Rough,
Neutral, Left and Right tool. Also, Grooving and Parting operation is performed on the left side of the shaft.

3. DRILLING: This machine drills the diameter 4.5 dowel hole which is used as reference for further operations.

4. GRINDING JOURNALS: Here grinding and finish grinding of the 6 journals takes place. Carborundum wheels are
used for grinding.

5. GRINDING ON FACE: An angular grinding wheel is used for the face grinding operation. At this stage,
inspection is done after every 10 components using gauges.

6. DRILL DOVEL HOLE: Grinding of the Cam is done here. The dowel hole is taken as the reference.

7. LAPPING: To give superfinish in microns, lapping is done using lapping paper on the Cams and the Oil seal
area.

8. SLITTING: This machine makes a slit in the right side of the shaft to fit in the engine. The cutter used is a
Saw cutter and pneumatic deburring is done here.

9. AIR & WATER CLEANING: This is the Washing Machine where water and air jets are used to clean the
component of dust, oil, chips etc

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ADVANTAGES OF CAM SHAFT:

1. camshaft increases natural frequency of the valve train.

2. Dynamic characteristics of the value actuating mechanism make it possible to design camshaft
profiles which expand the usefull operating range of high speed engines.

3. Camshaft profiles which expand the useful operating range of high speed engine.

APPLICATIONS:

1. In automobile engines
2. In piston engines
3. Electric motor speed controllers
4. Engine ignition systems

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CAMSHAFT DIMENSIONS:

PARTS:

DIAMETER LENGTH
1.44mm 60mm
2.50mm 40mm
3.64mm 5mm
4.60mm 20mm
5.64mm 5mm
6.50mm 20mm
7.75mm 20mm
8.50mm 65mm
9.64mm 30mm
10.50mm 45mm
11.75mm 20mm
12.50mm 32.5mm
13.60mm 20mm
14.50mm 57.5mm
15.44mm 60mm

CENTER DISTANCE for part no 7and11 in 10

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CONCLUSION:

Cast Camshaft

When purchasing a camshaft, enquire which material the camshafts are produced
from. A chilled iron camshaft may be more expensive, but its resistance to wear in
all conditions, far exceeds any other type of cast iron.

Steel Camshaft

In general, steel is a good camshaft material. However, the type of steel has to be
matched with the cam follower it runs against, as different grades of steel have
different scuff characteristics.

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FUTURE SCOPE:

1.The Automotive Camshaft Market is mainly driven by increasing demand for passenger cars

and commercial vehicles in the emerging economies of the world. Owing to advantages such as

smooth surface finish, dimensional accuracy and others, demand for casted automotive

components has shown a considerable increase. This trend is expected to continue and

demand for cast camshaft is expected to show a significant uptake in the market. Growth in the

sales of passenger cars and commercial vehicles will directly impact the Automotive Camshafts
market.

2.OEM segment is expected to drive the growth of the Automotive Camshaft Market.

Owing to their durability and high strength, the replacement rate of automotive

camshafts is low. Currently, camshaft manufacturers are focusing on producing light

weight and more durable products, which will increase the life span of automotive

camshafts as well as automobile. This will increase the OEM segment share in the Automotive
Camshaft Market.

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REFERENCES:

1. Georgano, G. N. (1982). The New Encyclopedia of Motorcars 1885 to the Present (Third
ed.). New York: E. P. Dutton. p. 407. ISBN 0525932542. LCCN 81-71857.
2. Culshaw, David; Horrobin, Peter (2013). The Complete Catalogue of British Cars 1895 –
1975. Poundbury, Dorchester, UK: Veloce Publishing. p. 210. ISBN 978-1-845845-83-4.
3. Boddy, William (January 1964). Random Thoughts About O.H.C.Motor Sport. London,
UK: Teesdale Publishing. p. 906. Retrieved 7 June 2020.

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