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CAMSHAFT AND TAPPET

TEST RIG
PRESENTATION SUMMARY
 Introduction
 Overview of the Camshaft and Tappet
system.
 Load conditions and environment
 Failure and wear
 The Rig
 Conclusions

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OVERHEAD CAMSHAFT
WITH INVERTED BUCKET
FOLLOWER

 Overhead camshaft
with inverted bucket
follower is the
configuration type
selected for our Test
Rig
 Camshaft acts directly
onto the tappet and
directly actuates the
valve
Stone, R, Introduction To Internal
Combustion Engines [1]
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CAMSHAFT LOBE FEATURES

 The Camshaft lobe has three

main features
1) Ramp
2) Flank
3) Nose
What are their
characteristics?
Acceleration
Valve lift proportional to
lobe radius
Zero velocity at maximum
lift (turning point)
Heisler, H, Advanced Engine Technology
[2]

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 LOAD CONDITIONS AND
ENVIRONMENT
 Diagram shows the force at
the tappet with respect to
camshaft angle
 The three curves
represent different
engine speeds
 Maximum force is not
necessarily at maximum
valve lift.
 Inertial force overcomes
spring force due to Stone, R, Introduction To Internal Combustion
Engines[1]
increased acceleration

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FATIGUE FAILURE (PITTING)

 Fatigue accounts for

90% of failure in metals
 Biggest culprit of
camshaft failure.
 Cracks propagate Pitting and spalling on a cam lobe (above) and
under the surface due tappet (below)

to shear stresses.
 Correct materials
selection and
processes can prevent
this. www.tribology-abc.com [3]

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FAILURE ANALYSIS

 Microscopy images
 Top image shows
formation of fatigue
cracks and broken off
material
X 50 Mag  Bottom image shows
loss of material due to
fatigue, combined with
abrasive wear.
 These images show camshaft
surface fatigue and abrasive
failure.
 The cause of this is due to a
X 50 Mag build-up of Hertzian stresses
under the surface.
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THE DESIGN
Torque
transducer

Drive pulley

Test bed

• To be situated
on trolley:
•Motor
•Clutch
•Oil pump
Plummer block Camshaft
•Sump
•Heater
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 DESIGN FEATURES

 Simulated valve mass.

 Adjustment for valve spring

compression.

 Probe type displacement

sensor attached to rod.

 Section through tappet and

housing
 Shims to allow for
larger or smaller
springs
 Dual spring retainers AEROSPACE COATINGS LTD
DESIGN FEATURES

Shims allow for

tappet rotation
Oil grooves on tappet

Tappet configuration
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CYLINDER HEAD TEST RIG

Fiat 1.9 JTD engine in place on the cylinder

head test rig.

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CONCLUSIONS

 The use of a Camshaft and Tappet test rig is highly

beneficial
 Simulates dynamic environments
 Results can be applied to all aspect of material
testing.
 Excellent example of a harsh tribological environment
 Fatigue testing
 Cost and time effective
 Easy to analyse, prepare and set-up

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REFERENCES

[1] Stone, R – Introduction to Internal Combustion Engines, The

Macmillan Press, 2nd Edition 1992, ISBN 0-333-55083-6
[2] Heisler, H - Advanced Engine Technology, Butterworth-Heinemann,
1st Edition 2002, ISBN 0-340-56822-4
[3] http://www.tribology-abc.com/poll/case03.htm-accessed 2/12/04
[4] http://www.hbm.com/products/ - accessed 1/04/05