Cam Profile Modification

In order to achieve over expanded cycle , cam profile modification is a necessary. The
intake profile is modified to delay the time where the intake valve is closed. This is because in
over expanded cycle , the compression ratio is up from 8 to 17. Intake valve should close a bit
late to prevent the pressure in cylinder is too high. According to advice from Prof. Horizon ,the
intake valve should close when the piston in the compression stroke is in the half way to achieve
TDC ( Top Dead Center ). This also means that the intake profile will shift 45 0 more after the
piston reach BTC ( Bottom Dead Center ) in Intake Stroke.

Intake Profile after modification

Original Exhaust Profile

To fabricate a new cam , CNC is used since it required highly precision. For my design , I
decide to fabricate 3 single parts and assemble them. The 3 parts consists of a gear for timing
belt, a connector and a cam.

Nice fitting gear for timing belt Less accurate dimension gear for
with correct dimension timing belt
 The connector which used to join
the cam and the gear for timing
belt

The new modify cam

Cam is a very important part since it controls the intake valve and exhaust valve. Cam
must be hard enough because as long as the engine is running , the cam will need to crank the
arm which connect to the intake valve and exhaust valve. Therefore , a surface hardening test
has been run to observe the changes on the harden surface. A same material metal is heated up
by technician using gas welding and some powder is poured on it. Lastly , the metal is heated
again and cooled it by putting it in water.

Harden surface

Original surface