The maximum force on spring (Pog) Hive” P+ dad 88.46 + 10 (25) = 348,90 N : wen) Step it The Wahl factor is given by, xe Wire diameter AC=1 0.618 | A@)= 1, 0.015 1x4 ac-4 °C 4-4 838 son) ¢ =~ } or 300 = 1.184 Step U1 Mean coil diameter D=Cd= 8(6) = 48 mm Step IV Number of active turns d* 6)" Nw Oo CA IUINSEE 3013 0F- 13 8D*k —8(48)°(10) Step V_ Total number of turns For square and ground ends N,=N+2=134+2=15 Step VI Maximum compression of spring 5. — SPomD'N _ 8(338.36)(48)°(13) oe Gd* ~~ (84x10° 6)" 75mm Step VII Solid length of spring Solid length = N, d= 15(6) = 90 mm Step VIII Free length of spring Free length = solid length + dings + 0.15 Snax = 90 + 35.75 + 0.15 (35.75) 131.11 mm Step IX Pitch of coils Pitch of coils = SSE Hength _ 3L-IL. 4, itch of coils= Tee UBM ILM aged 6 05-Ven or Example 25.23 Design the valve. ‘gear mechanism Jor the exhaust valve of a horizontal diesel engine using the following data: Cylinder bore = 250 mm Length of stroke = 300 mm Engine speed = 450 rpm LS sssure = 3.5 MPa Maen tag of each arm = 150 mm Angle between two arms = 165° Seat amgle of valve» 45° Mass of valve = 0.5 kg ‘Back pressure when the exhaust valve open, 94 Mp, Maximum suction pressure = 0.02 MPa (ye), aim » before outer dead con. The valve opens and closes 1° after inner dead centre, The yajy." to open and close with constant acceleratign 4 deceleration for each half of he lift. Assume sutayy, data and state the assumptions you make Solution Given D=250mm /=300mm N~=459 5 MPa=3.5 N/mm? a= 150mm m=0.5kg a= 45° 0.4 MPa = 0.4 N/mm? .02 MPa = 0.02 N/mm? "pm Part 1: Design of valve Step I Diameter of valve port nes | mm? 4 v= mean velocity of piston e425 K) ~ “ea “(i000 J 60) Assume [from Table 25.2), v, = 50 m/s nd = Therefore, axv=a,xv, (250) Y (2) 450) nd? a =| =2 |x 0) ( 4 )**\i000 ) 60 aye dj = 5625 mm? d,=75 mm @ Step I Diameter of valve head Foraseatangle of 45°, the projected width ofthe valve seat is given by following empirical relationship EES... ltiw oe or W= 0.06 d, = 0.06 (75) «4 The diameter of the valve head (4 ; mm = (d, + 2w ,) is give d,=(dy+2W)=75 42x45 84 watt en by, step III Thickness ofthe vate heng (ii) For steel valve, : a Assume 0} = 70 Nim? ieee a m = = (0.42\(75) [35 oy * 8 = (25 75 = [Fesas| to [2 ul 15.73 to 20.38 mm 18mm (iv) Step V- Maximum: lift of valve dy 75 Sa Feos (dsp = 26520r27 mm (¥) h, Part 2: Forces acting on rocker arm The gas load P, is given by, = (742), _( 284? a-( = Jre=( 7 Joa) 2216.71 N @ The initial spring force P, is given by. _( #4), _ (24? a= 2 \p.=( , ova, = 110.84 ©) The acceleration of the valve is calculated by using the following steps: (Speed of camshaft For four-stroke engine, 1 Speed of camshaft = 5 (speed of crankshaft) (ii) Angle turned by camshaft per second Since, 1 revolution = 360° (iii) (iv) Angle tumed by camshaft per second (Number of revolutions/s (360°) (2 360) ” a Je ) = 1350? per s In other words, 1350° of cam rotation wakes 1 second. Total crankshaft angle when the valve is open = 33 + 180+ 1 =214° Total angle of cam action For four-stroke copie 1 angle of camshaft= > (angle of crankshaft) a 2 = 7 @214)= 107 ‘As shown in Fig. 25.41, during half of this rotation, the valve will open and in the remaining half, the valve will close. Therefore, ‘cam rotation for valve opening is (107/2) or 53.5°. Out of this, half the angle is occupied by constant acceleration and half the angle by constant deceleration. Therefore, cam rotation during the constant acceleration period is (53.522) or 26.75°. The valve lift is 27 mm. The valve will be raised by (27/2) or 13.5 mm during constant acceleration and 13.5 mm during the constant deceleration period. Fig. 25.41 Cam angle during constant acceleration = 26.75"Valve lift during constant acceleration (s) = 13.5 mm= 13,5 109m ©) Time taken by valve during constant acceleration period Since, 1350° of cam rotation = 1 second Time taken by valve during constant acceleration period (1) E Angle of cam action Angle turned by camshaft per second 26.75 ==> , mea " = 125 Substituting, 4683.59 5* 7 (25d) d,=2737 or 30mm 1, = 1.25d, = 1.25 (30)=37.5 oF 40 mm The pin should be checked for doubje d? = 749.37 Shee stress, The shear stress is given by, Ry 4683.59 = Fay ty = 3:31 Nimoy? e nd? 2 (30) A 4 1<42 N/mm? The outside diameter of the boss ofthe rock, arm at the fulcrum pin is assumed as twice yg diameter of the fulerum pin. Outside diameter of boss at fulcrum pin = 2d, = 20) = 60 mm ; A phosphor bronze bush of 3 mm thickness i press fitted in the pinhole of the rocker arm, Inside diameter of hole at the boss = d, +3 <2 - 30+3x2=36mm The cross-section of the rocker arm pasing through the fulcrum pin is shown in Fig, 25.42 1 us check this cross-section for bending stress, }+— 40 —»} ‘ My = P. x a= 2362 x 150 = 354.3 x 10° N-mm 1 = 40)x(60)> _ (40) 36) 12 R (40)[(60)* — (36)°] = 564.48 x 103 mm*230mm 9343x1000) pi = (564.48 10°) oes, oN Cah pot corked ene ‘oe ‘es a roller that revolves on the ee 8.83 Nimm? Jc 1 ytd Oring on te roller pin is P. Beppe p= Pa 2362 N sa et of roller pin (mm) 7 bi of roller pin (mm) ng he bearing atthe roller pin, (p)= 5 Némm?) (Iold,= 1.25) 219.44 of 20 mm 125d, = 1.25 (20) = 25 mm sis given by, ‘he shear stress 3.16 Nimm? <4 Nim? The roller pin ofthe eye are as follows Thickness of each eye = Outer diameter of ey! is fixed in the eye. The dimensions [2 = 25/2 = 12.5 mm 1, = 2d; = 2(20) 40mm ‘The diameter ofthe roller should be more than the outer diameter of the eye by at least 5 mm. Diameter of roller =40+5=45 or 50 mm When the roller pin is tight in the two eyes of the fork, failure occurs due to shear. On the other hand, when the pin is loose, it is subjected to tending moment. It acts as a beam as shown in Fig. 25.38. It is assumed that the load acting on the pin is uniformly distributed in the portion that is in contact withthe roller. Its uniformly varying in 0 parts of the fork. ee Seeveais ‘maxirmum at the central ‘the pin. From Eq. 25.89, ™~ Design of C Engine Components 912 5 yap =(& Ply -(Z) eae = 12302.08 N-mm_ nd} _ x(20)) 32 32 M, _ 12302.08 12302.08 _ 15,66 N/mm? 785.4 Se 35.4 mm 6,< 70 Nimm* lection of rocker arm the arm is subjected 10 action of the force Pe: Part 5: Design of cross-s As shown in Fig. 25.39(@), bending moment under the We will consider the cross-section of the erm near the boss ofthe fulerum pin. The outside diameter of the boss ofthe rocker arm atthe fulerum pin twice the diameter of the fulerum pin (241). ‘Therefore, My=P,(a—d\)=2362 [150-30] = 283.44 x 10° N-mm ‘The proportions of cross-sec! arm are shown in Fig. 25.43. tion for the rocker G1) P=328.31 1=69 or 7mm ‘The dimensions of cross-section as shown in Fig. 25.43 are as follows:Width of flange = 2.54 2.5(7) = 17.5 mn Depth of section = 6r = 6(7) = 42 mm Part 6: Design of tappet tappet is a stud, which is subjected to compressive force (P,). Suppose, 4.= core diameter of stud (mm) @&= 60.15 ,= 7.76 mm The nominal diameter (d) of the stud is given by, nae or 10 mm 8 08 The diameter of the circular end of the rocker Aan (2s) and its depth (4) are calculated by the following relationships: D3 =2d=2(10)= 20mm 45 = 2d=2(10) =20 mm Part 7: Design of valve spring Assumptions (i) The spring index is 8, (i) The stiffness of spring is 10 N/mm, (Permissible torsional shear stress for the Spring wire is 300 N/mm2 (iv) Modulus of rigidit 84x 103 N/mm? ty for the spring wire is Step 1 Maxim tum force on spring The initial spri ing force P, is calculated as, P,= 110.84 N " moon spring (P...) is given Y, Prax. = Pi + kB= 110.84 4 10 (27) SORA NIE > mm) Step Il Wire diameter The Wahl factor is given by, =4¢-1 0.615 (8) —1 0.615 4c-4* 4@)—4 5g 1.184 8Fra ©) op 300 =1.184{ 4040-444) rR Se nd? d? = 30.62 d=5.53 or 6mm Mean coil diameter ed D=Cd=8 (6) = 48 mm Step IV Number of active turns (84 x 10°)(6)* 8(48)°(10) Step V Total number of turns For square and ground ends N,=N+2=13+2=15 =12.3 or 13 Step VI Maximum compression of spring 8Frnax.D?N _ 8380. 84)(48)3(13) Sax Gd Bax KH = 40.24 mm Step VIT Solid length of spring Solid length = N, d= 15 (6) = 90 mm Step VIIL_ Free length of spring Free length Step IX Pitch of coils ‘ iis = feellength _ 136.28 Pitch of coils = Bore tsay =9.73 mm Part 8: Design of cam The diameter of camshaft following empirical relatio i (D/) is obtained by the nship: 16D + 12.5 where, D = cylinder bore (mm) D’=0.16D + 12.5=0.16 (250) + 12.5 = 52.5 or 55 mm. The base circle di