3.

Mouse, Key board etc

SOFTWARE REQUIRED:-

CATIA.

MATERIALS:

Medium carbon alloy steel.

Production process

Drop forging and machining.

DESIGN PROCEDURE FOR CAM SHAFT:-

If
1. 2 cams are available in between two journals (or)
supports of cam shaft=camshaft dia dc = 0.3 B

2. 4 cams are available in between two journals (or) supports of cam shaft=camshaft dia dc =
0.35 B
3.8cams are available in between two journals (or)supports of cam shaft=camshaft dia dc = 0.4 B

Assume,

Maximum permissible deflection of the cam shaft under input load due to valve opening
= 0.075 mm

we know that,
y =PL3 / 6 EI [2x4 + 2x2 - 4x3]

Where

P = maximum impact load

L = distance between center of two journals
E = young’s modulus
I = moment of inertia of the cam shaft
= / 64 (Dc) 4
x = xL / L
xL = calculate from crank shaft diagram
L = calculate from crank shaft diagram

From crank shaft diagram

L = [(front main journal length of crank shaft / 2) + (flange thickness) + (thickness
1

Of Short crank arm) + (flange thickness) + (length of first crank pin / 2) +

(C.D) + (Length of second crank pin / 2) + (flange thickness) + (thickness of
Short crank arm) + (flange thickness) + (length of intermediate main journal of
Crankshaft / 2)]

Assumption:

Center of the front journal of crank shaft lies on the center of the front journal of cam
shaft (length wise)
Similarly center of the intermediate journals of the crankshaft and cam shaft lies on the
same axis.
Similarly center of the rear journal of the crankshaft and cam shaft lies on the same axis
Center of the crank pin (length wise)must be the center of the cylinder bore

L1 = distance between the center of the front to main journal of the crank shaft and
intermediate main journal of the crank shaft

L2 = distance between the center of the intermediate journal and rear main journal of
the crank shaft

X L1 = distance between the center of the front journal of the cam shaft and center
of the exhaust cam of the second cylinder.

XL1= L1 - [Intermediate journal length of crank shaft / 2 + (flange thickness) +

(Thickness of short crank arm) + (flange thickness) + crank pin length / 2 –
5 – Exhaust valve head / 2]

XL2 = distance between the center of the front journal of the cam shaft and center of
the exhaust cam of the third cylinder.
 C.D = the center distance between two crank pins

C.D = B / 2 + t + (water jacket thickness) + t + B / 2

DESIGN PROCEDURE FOR CAM PROFILE:

The function of the oil control ring is evident from their name. To perform this
effectively they must prevent excessive amount of oil from passing.

1.Between the ring face and cylinder wall

2.Through the ring end gap and
3.Around behind the ring

MATERIAL FOR PISTON RING:

1.Cast iron for piston rings:

SAE 113
SAE 114

Silicon = 2.5 to 2.8 %

Sulphur = not over 0.1
Phosphorous = 0.5 to 0.7 %
Manganese = 0.6 to 0.8 %
Combined carbon = 0.6 to 0.8 %
Total carbon =3.5 to 3.8 %

2. Ni-Cr iron

3. Ni-Cr-Mo iron

PRODUCTION OF PISTON RINGS (CENTRIFUGAL CASTING):

The original method of making ring blanks considered in pouring, “pot casting “,
that is long hollow cylinders, from which, after turning and boring, the rings were cut off
in the lathe.
 Radial thickness, br = D [(3 Pw) / ( t)]

Pw = Cylinder wall pressure, N/mm²

(0.0245 to 0.042 N/mm²)

t = Permissible stress in bending.

= 84 – 112 N/mm²

Axial Thickness, h = (0.7 – 1) br

Similarly h = D / 10 i

Where,
i = no of rings

The circumference of the ring in the close state = [ (B – T) – 0.003 x B]

The circumference of the ring in the free state = x B

When the ring is in the free state,

Outer diameter = B + T
Inside diameter = B – t
Mean diameter = B
Gap in the free state = B - [ (B – T) – 0.003 x B]

Angle subtended by the gap at the center is calculated from r = t + 0.003 B

RESULT:
Thus the piston pin and piston ring is designed & drawn using CATIA

DESIGN OF RING GEAR DESIGN INCLUDING THE DEVELOPMENT

OF RING GEAR TEETH

AIM:

To determine the design of ring gear including the development of ring gear teeth .
APPARATUS USED:

Software: CATIA.
Hardware: 4 GB RAM, Keyboard, and Mouse.

PROCEDURE:

Ring gear design as per the standard starter pinion, specification available in SAE
handbook.

Depth of ring gear excluding teeth can be taken between 12 to 16 mm

Width of ring gear can be taken between 16 to 18 mm,
Involute tooth profile is used for developing the tooth

STANDARD PINION DETAILS

Use Dp Root dia Outside Standard Pitch dia

duty No. Of (inches) dia Pressure pinion (inches)
teeth (inches) angle ( ) blank

Light 10/12 9 0.787 1.167 200 10 1

Light 8/10 10 1.125 1.575 200 11 1.875

Gear ratio between standard pinion and ring gear lies between 9:1 to 11:1
Take the necessary values from the tabular column of standard pinion details

The addendum and dedendum values of starter pinion are same as that of addendum and
dedendum values of ring gear.

Data for starter pinion:

All Dimension Are In Inches

S.no Diameteral No of teeth in Root Outside Pitch Pressure

pitch pinion Diameter Diameter Diameter Angle
1
2
3
4

Dg = Pitch circle diameter of ring gear

Dg = D7 + 2 (4) + 2 (dedendum)
Dedendum = Pcd - Root dia / 2
Diameteral pitch = I / D

From this calculate the number of the teeth on ring gear

The gear ratio is between 9 to 11

Ratio of ring gear to pinion = Ring gear teeth / Pinion teeth

DESIGN OF TOOTH PROFILE:

Basic circle diameter = 2 x (Pcd x cos θ) / 2

Where,
θ = pressure angle
Pcd = pitch circle diameter of ring gear = d8

TOOTH ANGLE:

Tooth angle = 360◦ / 2n

Thickness of teeth = x Pcd / 2n

CALCULATION:

Pitch circle diameter of ring gear

D8 = D7 + 2(4) + 2 (dedendum)

No of teeth in ring gear = 91.411 Ω 92 teeth.

 The ratio of ring gear to pinion = Ring gear teeth / Pinion teeth

DESIGN OF TEETH PROFILE:

Base circle diameter = 2 x (Pcd x cos θ / 2) (θ = pr angle = 20)

=

Tooth angle θ = 360• / 2n

Thickness of teeth = x Pcd / 2n

RESULT:

Thus the cam profile is designed & drawn using CATIA.