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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system

Push-Rod Design for
Performance Four-Stroke
Engine Valve Actuation system

Name: Arun Vimalathas ID: 1108527
Name:
















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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system
Contents
Introduction .................................................................................................................................................. 3
Fundamentals ............................................................................................................................................... 3
Push-Rod Geometry ...................................................................................................................................... 4
Specifications and information given ........................................................................................................... 5
Design Calculations ....................................................................................................................................... 5
Appendix Table ............................................................................................................................................. 7





Table of figure















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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system
Introduction
Designing the lightest push-rod for a Four-Stroke engine vale actuator system, so that the engine will get
maximum speed is the aim of this project. Fuel is burned inside the combustion chamber for every
stroke in a four-Stroke engine. Valves are used to bring the air-fuel mixture into the combustion
chamber and to push out the exhaust gases out of the chamber. Explosion during the combustion moves
the piston up and down which makes the vehicle to move.
Therefore the car to be moves fast (or to get maximum engine speed) the valves must be able to open
and close very fast so that combustion happens at faster rate. To actuate the valve system at faster rate
cam shafts are used. Cam shafts are placed next to the crank shaft and both of them are coupled by a
timing chain. Toothed gear configuration is used to drive both cam shaft and crank shaft.

Figure 1: Operation of Four-Stroke Engine (Image reprieved from http://what-when-
how.com/automobile/operation-of-reciprocating-piston-ic-engines-automobile/)

Fundamentals
As each cam shaft sprocket rotates it drives the cam follower away from the camshaft rotational axis.
Then the cam follower converts the circular motion into a linear motion along the axis of Push-rod. The
linear motion of the cam follower is transmitted to one end of the push-rod. The motion is then
transmitted to the rocker arm by the other end of the push-rod. The rocker arm rotates about its pivotal
point and other end of the rocker arm transmit the movement to the valve spring. The valve springs
moves in the axis of push-rod as they move up and down to open and close the valves.

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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system

Push-Rod Geometry
Push-rods are used only on cam-in-block engines. Push-rods transmits the lifter motion they obtained
from the cam follower to the rocker arm which actuated the valves. Cross section of the pushrod is to be
circular. Circular cross section means there are no sharp edges. Sharp edges makes stress concentrated
areas and leads to failure of the part. To eliminate the stress concentration failure a circular cross
sectional Push-rod is considered. Using a circular cross sectional push-rod also gives smaller second
moment of inertia (I) which means smaller diameter can be obtained for the same amount force acting
on the push-rod than other shapes. Smaller diameter means lighter push-rod therefore it can get to the
high engine seed.

Figure 2: Push-rod ( Image retrieved from
http://upload.wikimedia.org/wikipedia/commons/d/d8/Pushrod2.PNG)
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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system

Specifications and information given
Valve opens: 66 BTDC
Valve closes: 66ABDC
Maximum Valve lift: 12.7 mm
Maximum cam follower velocity: 0.018 mm/camshaft
Minimum cam follower acceleration: -0.008 mm/camshaft 2
Maximum cam follower acceleration: +0.018 mm/camshaft 2
Base circle diameter: 19 mm
Weight of the cam Follower: 50 g
Maximum Push rod Diameter: 7mm
Design Calculations
Finding Spring Constant
0.25 Inches of compression requires 75 lb of mass
0.25 inch = = 0.635 cm
75 lb = 750.453599.81= 333.79 N



0.5 Inches of compression requires 225 lb
0.5 inch=
225lb=

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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system

Spring compression force Fx





Inertia force F
f


Acceleration

A
f
=

A
f
=2.583 mm/s^2
F
f


F
f
N
Total Dynamic force = F
f
+ F
x
Total Dynamic Force
(

)


Total Dynamic Fore = 9.846 N
Static Force
Static force = 1501.786 N
Maximum Axial force acting on the Push-Rod
Maximum Axial force acting on the Push-Rod






Finding Diameter of the Push-Rod

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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system

I for circular cross section is d^4/64

Mass of the Push-rod ==
Volume of push-rod
Volume of push-rod

Volume of Push-rod

Density of AISI 1040 Carbon Steel

Mass of the Push-rod

Mass of the push rod= 0.0692 Kg








Appendix Table

Properties Metric Imperial
Tensile strength 620 MPa 89900 psi
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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system
Yield strength 415 MPa 60200 psi
Bulk modulus (typical for steels) 140 GPa 20300 ksi
Shear modulus (typical for steels) 80 GPa 11600 ksi
Elastic modulus
190-210
GPa
27557-30458
ksi
Poissons ratio 0.27-0.30 0.27-0.30
Elongation at break (in 50 mm) 25% 25%
Reduction of area 50% 50%
Hardness, Brinell 201 201
Hardness, Knoop (converted from Brinell hardness) 223 223
Hardness, Rockwell B (converted from Brinell hardness) 93 93
Hardness, Rockwell C (converted from Brinell hardness. Value below normal HRC
range, for comparison purposes only)
13 13
Hardness, Vickers (converted from Brinell hardness) 211 211
Izod impact (annealed at 790C (1450F)) 45 J 33.2 ft-lb
Izod impact (as rolled) 49 J 36.1 ft-lb
Izod impact (normalized at 900C (1650F) 65 J 47.9 ft-lb

The mechanical properties of AISI 1040 carbon steel

Properties Metric Imperial
Density (chemical composition of 0.435% C, 0.69% Mn, 0.20% Si, annealed at 860C
(1580F))
7.845
g/cc
0.2834
lb/in
Melting point 1521C 2770C

The physical properties of AISI 1040 carbon steel








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Push-Rod Design for Performance Four-Stroke Engine Valve Actuation system





Reference
http://everything2.com/title/Internal+combustion+engine+valve+actuation+methods
http://www.g-w.com/pdf/sampchap/9781605250526_ch05.pdf
http://www.azom.com/article.aspx?ArticleID=6525