International Journal of Research e-ISSN: 2348-6848

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Volume 04 Issue-17
December 2017

Modeling and Fatigue Analysis of Metal Matrix Composite Cam

Shaft Using Finite Element Analysis
Jarpula Nirmala & Kanjarla Shyam Kumar
1
pg Scholar, Dept of Mech, Warangal Institute of Technology and science, Oorugonda, Warangal, T.S,
INDIA-506342
2
Assistant Professor, Dept of Mech, Warangal Institute of Technology and science, Oorugonda, Warangal, T.S,
INDIA-506342
Abstract:
A camshaft is a shaft to which a cam is fastened or of
which a cam forms an integral part. In internal
combustion engines with pistons, the camshaft is used to
operate poppet valves. It then consists of a cylindrical rod
running the length of the cylinder bank with a number of
oblong lobes protruding from it, one for each valve. the
rotation of the camshaft and the rotation of the crankshaft
Fig 1 Cam shaft
is of critical importance. Since the valves control the flow
Introduction
of the air/fuel mixture intake and exhaust gases, they must
A cam is a mechanical device used to transmit motion to a
be opened and closed at the appropriate time during the
follower by direct contact. The driver is called the cam and
stroke of the piston.
the driven member is called the follower. In a cam
This camshaft is rotate at high speeds causing
follower pair, the cam normally rotates while the follower
vibrations in the system. Camshafts are also subjected to
may translate or oscillate.
varying contact fatigue loads due to the contact of the
plunger on the cam. Camshafts are rotating components
with critical load; these exact values are needed to be
determining to avoid failure in camshaft.
Here in this project modeling of camshaft is done in solid
works 2016 design modeling software and Static analysis
is carried out to find stress, strain and deformtion due to Fig : cam and cam shaft
applied load, and Fatigue analysis is carried out in ansys The camshaft is driven by the engine's crankshaft through
16 to find its life , Damage and Factor of safety in ANSYS a series of gears called idler gears and timing gears.The
work bench software by using two different material one is gears allow the rotation of the camshaft to correspond or
generally used Alloy steel (42CrMo4) and other is be in time with, the rotation of the crankshaft and thereby
Aluminium Metal Matrix material ,on given load allows the valve opening, valve closing, and injection of
condition. fuel to be timed to occur at precise intervals in the piston's
travel. To increase the flexibility in timing the valve

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Volume 04 Issue-17
December 2017

opening, valve closing, and injection of fuel, and to of the camshaft. In addition camshaft can include a gear to
increase power or to reduce cost, an engine may have one drive the distributor and an eccentric to drive a fuel pump.
or more camshafts. Typically, in a medium to large V-type Camshaft is controlling the valve train operation.
engine, each bank will have one or more camshafts per Camshaft is along with the crankshaft it determines firing
head. In the larger engines, the intake valves, exhaust order. Camshaft is along with the suction and exhaust
valves, and fuel injectors may share a common camshaft systems it determines the useful rpm range of the engine.
or have independent camshafts. Depending on the type Camshaft is used in the engine for transfers motion to inlet
and make of the engine, the location of the camshaft or & exhaust valve. If transfer of motion is not proper then
shafts varies. The camshaft(s) in an in-line engine is the stokes will not work in proper way. Also it effects on
usually found either in the head of the engine or in the top performance of engine. To make work of camshaft in
of the block running down one side of the cylinder bank. precise way. It is required in order to design a good
When the piston travels below the level of the ports, the mechanism linkage, the dynamic behavior of the
ports are "opened" and fresh air or exhaust gasses are able components must be considered; This includes the gross
to enter or leave, depending on the type of port. The ports kinematic motion and self-induced vibration motion.
are then "closed" when the piston travels back above the Dynamic models were created to obtain insight into
level of the ports. Valves are mechanically opened and dynamic behavior of the system prior to manufacturing.
closed to admit or exhaust the gasses as needed. The These models were mathematical tools used to simulate
valves are located in the head casting of the engine. The and predict the behavior of physical systems. They contain
point at which the valve seats against the head is called the systems properties which are masses, stiffness
valve seat. Most medium-sized diesel engines have either constants,and damping coefficients. The automotive sector
intake valves or exhaust valves or both intake and exhaust has reached a very high production capacity in the last
valves. decades. Depending on this increasing capacity, its stable
growth is anticipated in the world economy. The economic
value of the work capacity in the automotive sector is very
large and this shows that the automotive sector is the 6th
economic sector worldwide. The sector has an
interrelationship with more than 300 different fields. So, if
there is any malfunction in the main or side industries, the
whole functions of the produced cars are influenced. On
the other hand, the failure analysis is a special field of
Fig : rotation of cam shaft
study for materials and mechanical engineers. On one side,
Cam is a mechanical member for transmitting a desired
the materials engineer is intended to develop his/her
motion to a follower by direct contact. The driver is called
observational and reasoning skills for the understanding of
cam and driven is called follower. Cam mechanism is a
interrelationship between observable features and
case of a higher pair with line contact. Camshaft is the
properties or performance. On the other side, the
Brain of the engine must include cam lobes, bearing
mechanical engineer studies on the possible failure
journals, and a thrust face to prevent fore and after motion

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Volume 04 Issue-17
December 2017

locations and types and amount of the existent stress observable features and properties or performance. On the
levels. Many studies have been carried out on the other side, the mechanical engineer studies on the possible
automotive failure analysis is that the mostly failed parts failure locations and types and amount of the existent
are from engine and its components among the automotive stress levels. Many studies have been carried out on the
failures. This is followed by the drive train failures. automotive failure analysis is that the mostly failed parts
Among the studies on the engine component failures, the are from engine and its components among the automotive
prediction of fatigue failure in a camshaft using the crack- failures. This is followed by the drive train failures.
modeling method. Among the studies on the engine component failures, the
Camshaft is used in the engine for transfers motion to inlet prediction of fatigue failure in a
& exhaust valve. If transfer of camshaft using the crack-modeling method.
motion is not proper then the stokes will not work in A camshaft is a pole to which a cam is affixed or of which
proper way. Also it effects on performance of a cam structures a vital part. The camshaft is the most vital
engine.To make work of camshaft in precise way. It is part of an interior burning motor (internal combustion
required in order to design a good mechanism linkage, the engine). Its primary capacity is to control the valve timing,
dynamic behavior of the components must be considered; along these lines permitting intake valve to open at the
This includes the gross kinematic motion and self-induced right time for feeding fuel and air mixture into the engine.
vibration motion. Dynamic models were created to obtain The camshaft is driven by the motor's crankshaft through a
insight into dynamic behavior of the system prior to progression of riggings called idler apparatuses and timing
manufacturing. These models were mathematical tools gears. The riggings permit the pivot of the camshaft to
used to simulate and predict the behavior of physical relate or be in time with the turn of the crankshaft and
systems. They contain systems properties which are along these lines permit the valve opening, valve shutting,
masses, stiffness constants, and damping coefficients. The and infusion of fuel to be planned to happen at exact
automotive sector has reached a very high production interims in the cylinder's travel. To build the adaptability
capacity in the last decades. Depending on this increasing in timing the valve opening, valve shutting, and infusion
capacity, its stable growth is anticipated in the world of fuel, and to expand control or to decrease cost, a motor
economy. The economic value of the work capacity in the may
automotive sector is very large and this shows that the have at least one camshafts. Commonly, in a medium to
automotive sector is the 6th economic sector worldwide. expansive V-sort motor, each bank will have at least one
The sector has an interrelationship with more than 300 camshaft for every head. In the bigger motors, the
different fields. So, if there is any malfunction in the main admission valves debilitate valves, and fuel injectors may
or side industries, the whole functions of the produced cars share a typical camshaft or have free camshafts.
are influenced. On the other hand, the failure analysis is a Contingent upon the sort and make of the motor, the area
special field of study for materials and mechanical of the camshaft or shafts shifts. The camshaft(s) in an in-
engineers. On one side, the materials engineer is intended line motor is generally discovered either in the leader of
to develop his/her observational and reasoning skills for the motor or in the highest point of the square running
the understanding of interrelationship between down one side of the chamber bank. At the point when the

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cylinder goes underneath the level of the ports, the ports pushrods and rockers. Direct operation involves a simpler
are "opened" and outside air or fumes gasses can enter or mechanism and leads to fewer failures, but requires the
leave, contingent upon the kind of port. The ports are then camshaft to be positioned at the top of the cylinders. In the
"shut" when the cylinder goes back over the level of the past when engines were not as reliable as today this was
ports. Valves are mechanically opened and shut to seen as too much trouble, but in modern gasoline engines
concede or deplete the gasses as required. The valves are the overhead cam system, where the camshaft is on top of
situated in the head throwing of the motor. The time when the cylinder head, is quite common.
the valve seats against the head is known as the valve
situate. Most medium-sized diesel motors have either
allow
valves or fumes valves or both admission and fumes
valves.
CAMSHAFT OPERATION:
Camshaft Operation: Fig Position of cam shaft

The camshaft uses lobes (called cams) that push against TYPES OF CAMS HAFTS:
the valves to open them as the camshaft rotates; springs on Single Overhead Cam:
the valves return them to their closed position. This is a A single overhead cam has one cam per head. So if it is an

critical job, and can have a great impact on an engine's inline 4-cylinder or inline 6-cylinder engine, it will have

performance at different speeds one cam; if it is a V-6 or V-8, it will have two cams (one
for each head). On single and double overhead cam
engines, the cams are driven by the crankshaft, via either a
belt or chain called the timing belt or timing chain.
Double Overhead Cam:
A double overhead cam engine has two cams per head. So
inline engines have two cams, and V engines have four.
Fig 4 Cam shaft working
Usually, double overhead cams are used on engines with
Uses of cam shafts:
four or more valves per cylinder -- a single camshaft
In internal combustion engines with pistons mostly used in
simply cannot fit enough cam lobes to actuate all those
automotive industry, the camshaft is used to
valves. The main reason to use double overhead cams is to
operate poppet valves. It consists of a cylindrical rod
allow for more intake and exhaust valves. More valves,
running the length of the cylinder bank with a number of
means that intake and exhaust gases can flow more freely
oblong lobes protruding from it, one for each valve. The
because there are more openings for them to flow through.
cam lobes force the valves open by pressing on the valve,
This increases the power of the engine.
or on some intermediate mechanism, as they rotate.
Camshaft Basics
Position of cam shaft:
The key parts of any camshaft are the lobes. As the
Depending on the location of the camshaft, the cam
camshaft spins, the lobes open and close the intake and
operates the valves either directly or through a linkage of

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exhaust valves in time with the motion of the piston. It starts its compression stroke. So the faster the engine goes,
turns out that there is a direct relationship between the the faster the air/fuel moves, and the longer we want the
shape of the cam lobes and the way the engine performs in intake valve to stay open. We also want the valve to open
different speed ranges. To understand why this is the case, wider at higher speeds -- this parameter, called valve lift, is
imagine that we are running an engine extremely slowly -- governed by the cam lobe profile.
at just 10 or 20 revolutions per minute (RPM) -- so that it COMPOSITE MATERIALS:
takes the piston a couple of seconds to complete a cycle. It Composite material can be defined as a combination of
would be impossible to actually run a normal engine this two or more materials on macro scale with different
slowly, but let's imagine that we could. At this slow speed, properties, or a system composed of two or more
we would want cam lobes shaped so that: Just as the physically distinct phases separated by a distinct interface
piston starts moving downward in the intake stroke (called whose combination produces aggregate properties that are
top dead center, or TDC), the intake valve would open. superior in many ways, to its individual constituents. The
The intake valve would close right as the piston bottoms matrix acts as the building block which prevents any sort
out. The exhaust valve would open right as the piston of external damage to the composite whereas the presence
bottoms out (called bottom dead center, or BDC) at the of reinforcement is to improve its mechanical and thermal
end of properties such as strength, ductility, stiffness, toughness,
the combustion stroke, and would close as the piston thermal conductivity etc. i.e. the matrix can be thought to
completes the exhaust stroke. This setup would work be the parent material to which various alterations in
really well for the engine as long as it ran at this very slow physical, whereas mechanical and thermal properties are
speed. But what happens if you increase the RPM? Let's brought about by addition of fillers. Composite materials
find out. When you increase the RPM, the 10 to 20 RPM consists of two two constituents one is matrix and other is
configuration for the camshaft does not work well. If the reinforcement. The primary phase of a composite material
engine is running at 4,000 RPM, the valves are opening which is having continuous character and present in
and closing 2,000 times every minute, or 33 times every greater quantity is called matrix. The main function of this
second. At these speeds, the piston is moving very quickly, matrix is to acts as a binder and to hold the fibers in the
so the air/fuel mixture rushing into the cylinder is moving desired position thereby transferring the external load to
very quickly as well. When the intake valve opens and the reinforcement. While the other constituent is
piston starts its intake stroke, the air/fuel mixture in the reinforcement, can be either synthetic or natural fibers.
intake runner starts to accelerate into the cylinder. By the The mechanical property mostly depends upon the shape
time the piston reaches the bottom of its intake stroke, the and dimensions of reinforcement. Several natural fibers
air/fuel is moving at a pretty high speed. If we were to reinforced polymer composites are brought into the
slam the intake valve shut, all of that air/fuel would come competitive market for the demand of increasing
to a stop and not enter the cylinder. By leaving the intake environment security. Matrices which used are either
valve open a little thermoset or thermoplastic. Commonly used resins are
longer, the momentum of the fast-moving air/fuel thermoset matrix Polyester, Epoxy and phenolic. whereas
continues to force air/fuel into the cylinder as the piston polypropylenes, polyethylene and elastomers comes under

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thermoplastic matrix. used to analyze the critical area of the Cam shaft and
The most primary applications of composite materials are fatigue analysis tool life , damage and factor of safty is
found where high strength and low weight are concerned. find out finaly conclude the best material based upon
Few properties of composites accounted for their wider strength to weight ratio and life.
uses are high strength, low density, high tensile strength at SOLIDWORKS
high temperatures, high toughness, and high creep Solid Works is mechanical design automation software
resistance. that takes advantage of the familiar Microsoft Windows
Metal Matrix Composites (MMC): graphical user interface.
Metal matrix composites preferable instead of metals in It is an easy-to-learn tool which makes it possible for
few applications for the properties like High strength, low mechanical designers to quickly sketch ideas, experiment
co-efficient of thermal expansion, less weight. with features and dimensions, and produce models and
The composites which consist of metal alloys reinforced detailed drawings.
with continuous fibers or particulates I said to be MMC. A Solid Works model consists of parts, assemblies, and
These composites uses metals as matrix materials and they drawings.
have a higher temperature resistance than PMCs but they MODELLING OF CAM SHAFT
in general are heavier. The basic merit of metals Draw sketch as follows
reinforced with hard ceramic particles or fibers are
improved strength and stiffness. They also have improved
creep and fatigue resistance, increased hardness, wear and
abrasion resistance. MMC have wide range of applications
in combustion chamber nozzle, housings, tubing, cables,
heat exchangers, structural members due to their above Go to features and make revolve
properties.
scope of the project
The structural modeling of the Cam shaft needs to be
developed by using solidworks design software. Then
structural analysis and fatigue analysis are carried out in
ansys and suitable materials such as genral and composite
material are applied and began the meshing on the Cam
shaft. The finite element modeling (fem) processes were
Draw the sketch as follows and make extrude in feature to
performed. One end is fixed and loading is selected and
form cam shape
placed at the other end of Cam shaft. The finite element
analysis (fea) then carried out on the Cam shaft by
dividing the larger solutions into smaller solutions in the
form of partial differential equations.thus, producing the
result of stress, strain and displacement where it will be

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Fig: simulation example

FEM (Finite element method)

The software uses the finite element method (fem). Fem is
a numerical technique for analyzing engineering designs.
Draw the remaining cams as above
Fem is accepted as the standard analysis method due to its
Then draw the following sketch and make extrude
generality and suitability for computer implementation.
Fem divides the model into many small pieces of
simple shapes called elements effectively replacing a
complex problem by many simple problems that need to
be solved simultaneously.

Four views of cam shaft

ANSYS
Introduction
ANSYS delivers innovative, dramatic simulation
technology advances in every major Physics discipline,
along with improvements in computing speed and

INTRODUCTION TO SIMULATION: enhancements to enabling technologies such as geometry

Simulation is a design analysis system. Simulation handling, meshing and post-processing. These

provides simulation solutions for linear and nonlinear advancements alone represent a major step ahead on the

static, frequency, buckling, thermal, fatigue, pressure path forward in Simulation Driven Product Development.

vessel, drop test, linear and nonlinear dynamic, and Materials properties

optimization analyses. Material properties used for analysis are as follow

Powered by fast and accurate solvers, simulation enables

you to solve large problems intuitively while you design.
Simulation comes in two bundles: simulation professional
and simulation premium to satisfy your analysis needs.
Simulation shortens time to market by saving time and
effort in searching for the optimum design. ANALYSIS OF CAM SHAFT:
Model

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3D Modal after part IGES file transferred to ansys Mesh quality

workbench software

MATERIAL: Alloy steel (42CrMo4)

Stress
Stress achieved after analysis for alloy steel material.

Fixed support
Cam shaft is fixed at one end

Strain
Strain achieved after analysis for alloy steel material.

Load
500 N loads is applied on each cam.

Deformation
Deformation achieved after analysis for alloy steel
material.

Mesh
Uesd program controlled , tetrahedral shape and fine size
FATIGUE ANALYSIS
mesh
Life
Life of the cam shaft after analysis, for Alloy steel

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December 2017

Strain achieved after analysis for Al metal matrix

composite

Damage
Damage of the cam shaft after analysis, for Alloy steel
Deformation
Deformation achieved after analysis for Al metal matrix
composite

Factor of Safety
Factor of safety of the cam shaft after analysis, for Alloy
steel
FATIGUE ANALYSIS
Life
Life of the cam shaft after analysis, for Al metal matrix
composite

MATERIAL: Aluminium Metal Matrix

Stress
Stress achieved after analysis for Al metal matrix
composite. Damage
Damage of the cam shaft after analysis, for Al metal
matrix composite

Strain

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Factor of Safety  According weight Al metal matrix showing less

Factor of safety of the cam shaft after analysis, for Al weight compare to Alloy steel.
metal matrix composite  Meanwhile Aluminium metal matrix is showing
high life and less damage than compare to alloy
steel.
 Hence we can conclude that Aluminium metal
matrix is better material for cam shaft than
compare to alloy steel material, due to its less
weight to strength ratio, high strength , and better
Results high life.
Static Structural Results: References
[1] G.Wang, D.Taylor, B Bouquin J Devlukia, “Prediction
of fatigue failure in a camshaft using crack modeling
method,”Elsevier,Vol7,189-197,2000
[2] Vivekanandan P, Kumar M, “ Modeling ,Design and
Finite Element Analysis of Camshaft” IJCET, ISSN 2277-

Conclusion 4106, vol-3, No.1 , 2013

 Modeling and analysis of cam shaft is done. [3]Santosh Patil,S.F.Patil and Saravanan Karuppanam
“Modal and Fatigue analysis of a camshaft using
 Brief study about cam shaft, its applications,
FEA”IJAER,ISSN 0973-4562, vol-8,No.14, 2013
classification, and about composite materials is
[4] V.Mallikarjun, N Jashuva ,G Nagaraju, “Design
one in this project.
manufacturing and cost estimation of a camshaft used in
 Modeling of cam shaft is done in solid works 2016
two wheeler” , IOSR-JMCE, ISSN 2278-1684, vol.11,
design software.
issue-1,Ver-IV,PP 53-67, 2014
 Static analysis is carried out in Ansys work
[5]R.V.Wanjari, T.C.Parshiwanikar,“Design and analysis
bench16 by applying load on two different
of camshaft by changing parameters which causes
materials, one is generally used alloy steel
failure,”IJISME, ISSN:2319-6386,vol.1, Issue6, 2013.
material and another is Aluminium metal matrix
[6] R.V.Wanjari,T.C.Parshiwanikar,” Failure of
composite material.
camshaft“,IJITEE,ISSN:22783075,vol.2,Issue.6,2013
 Structural deformations such as stress,
[7] Suhas K.F., Dr.Mohmmad Haneef,”Contact fatigue
deformation and strain are studied and tabulated.
analysis using finite element analysis for 6 station lobe
 In Fractural tool, Life, Damage and Factor of
camshaft”,IJOAR, ISSN:2249-555,
safety on each material is noted and tabulated.
vol.4,Issue.7,2014
 From the results we can conclude that Aluminium
Metal Matrix composite (KS1275) is showing less
stress compare to Alloy steel (42CrMo4).

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