“Random Vibrations Analysis on Cam Shaft”

Submitted By

Name Registration Number

Haroon Yaseen Abbasi BME203019
Nokhaiz Mazhar BME203014
Jhon Haider Naqvi BME203015
Hamza kayani BME203072

A Project Report submitted to the

DEPARTMENT OF MECHANICAL ENGINEERING
In partial fulfillment of the requirements for the Finite Element Method
Of the degree of
BACHELORS OF SCIENCE MECHANICAL ENGINEERING

Faculty of Engineering
Capital University of Science and Technology
Islamabad
June, 2023

Copyright @2023 by CUST Student

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 DECLARATION

It is declared that this is an original piece of our own work, except where otherwise
acknowledged in text and references. This work has not been submitted in any form for another
degree or diploma at any university or other institution for tertiary education and shall not be
submitted by us in future for obtaining any degree from this or any other University or
Institution.

Haroon Yaseen Abbasi

BME203019

Nokhaiz Mazhar
BME203014

Jhon Haider Naqvi

BME203015

Hamza Kayani
BME203072

June, 2023

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 CERTIFICATE OF APPROVAL

It is certified that project titled “waste heat recovery shell and tube heat exchanger” carried out
by Nokhaiz Mazhar (BME203014), Jhon Haider Naqvi (BME203015), Haroon Yaseen Abbasi
(BME203019) and Hamza kayani (BME203072) under the supervision of Sir Tauseef Ahmed
Capital University of Science and Technology, Islamabad, is fully adequate, in scope and in
quality, as a semester project for the course of Manufacturing Processes.

Course Instructor:

Tauseef Ahmed
Professor
Department of Mechanical
Engineering Faculty of
Engineering
Capital University of Science and Technology, Islamabad

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 ACKNOWLEDGMENT

We are very thankful to Sir Tauseef Ahmed who guided us in our whole project and all other
members who is participating in this project Haroon yaseen, Nokhaiz mazhar, Jhon haider and
Hamza kayani.

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 Abstract

Random vibration analysis plays a crucial role in the design and optimization of mechanical
systems to ensure their reliable and durable performance. In this study, we focus on the
application of random vibration analysis techniques to assess the dynamic behavior of a
camshaft, a critical component in internal combustion engines.
The primary objective of the analysis is to investigate the effects of random vibrations on the
camshaft's structural integrity, as well as its functional performance under real-world operating
conditions. The camshaft experiences random excitations due to various sources, such as engine
firing impulses, component imbalances, and road irregularities. These random excitations can
lead to detrimental effects, including fatigue failure, excessive wear, and increased noise and
vibration levels.
To achieve this objective, a comprehensive numerical model of the camshaft system is
developed, taking into account its geometric and material properties, as well as the dynamic
interactions with other engine components. The model incorporates random vibration inputs
based on statistical characteristics derived from measured or estimated data sources, representing
realistic operating conditions.
The analysis employs advanced computational techniques, such as finite element analysis (FEA)
and Monte Carlo simulations, to predict the camshaft's dynamic response under random
excitations. The FEA provides insight into the modal characteristics, natural frequencies, and
mode shapes of the camshaft, while the Monte Carlo simulations enable the assessment of the
statistical distribution of response quantities, such as displacements, stresses, and strains.
Through the analysis, the study aims to identify critical locations on the camshaft prone to high
stress levels, potential fatigue damage, or excessive vibrations. This information helps engineers
and designers in implementing appropriate design modifications, such as material enhancements,
geometrical optimizations, or damping solutions, to improve the camshaft's reliability and
performance.
The outcomes of the random vibration analysis provide valuable insights into the dynamic
behavior of the camshaft and contribute to the development of robust and efficient designs. By
minimizing the potential risks associated with random vibrations, the study ultimately aims to
enhance the camshaft's lifespan, reduce maintenance costs, and improve the overall performance
and durability of internal combustion engines.

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Table of Contents
Chapter 1....................................................................................................................................................6
Introduction.................................................................................................................................................6
Objectives................................................................................................................................................6
Chapter 2....................................................................................................................................................7
Methodology...............................................................................................................................................7
2.1 Data Acquisition:...........................................................................................................................7
2.2 Signal Processing:..........................................................................................................................7
2.3 Finite Element Analysis (FEA):.....................................................................................................7
Chapter 3....................................................................................................................................................7
Results and Discussion............................................................................................................................7
3.1 Natural Frequencies:......................................................................................................................7
3.2 Frequency Response Function (FRF):...........................................................................................7
3.3 Stress Analysis:..............................................................................................................................7
Chapter 4....................................................................................................................................................8
Conclusion...............................................................................................................................................8
Recommendations...................................................................................................................................8
Chapter 5....................................................................................................................................................9
References...............................................................................................................................................9

Chapter 1
Introduction
The purpose of this report is to present the findings of a random vibration analysis conducted on

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a camshaft. Random vibration analysis plays a crucial role in evaluating the performance and
durability of mechanical components subjected to real-world operating conditions. In this study,
the camshaft's response to random vibrations is examined to assess its structural integrity and
reliability.
Random vibration analysis plays a critical role in the design and analysis of mechanical systems,
enabling engineers to understand and predict the behavior of components under real-world
operating conditions.
Camshafts are subjected to various sources of random vibrations during engine operation,
including engine firing impulses, component imbalances, and road irregularities. These random
excitations can induce dynamic loads on the camshaft, leading to fatigue failure, excessive wear,
and increased noise and vibration levels.
Finite element analysis (FEA) has proven to be a powerful tool for simulating and analyzing the
dynamic behavior of mechanical systems, including camshafts. FEA divides the camshaft into
smaller elements, allowing for a detailed representation of its geometry and material properties.
By applying the principles of structural mechanics, FEA can predict the camshaft's response to
various load conditions, including random vibrations.

Objectives
The main objectives of conducting random vibration analysis on a camshaft using finite element analysis
(FEA) are as follows:
1. Assess Dynamic Response: The primary objective is to evaluate the dynamic response of the
camshaft under random vibrations. This involves analyzing the displacement, stress, and strain
distributions throughout the camshaft structure. By understanding the camshaft's behavior under
random excitations, engineers can identify potential areas of concern and evaluate the impact on
its structural integrity.
2. Identify Critical Locations: Another objective is to identify critical locations on the camshaft that
are prone to high stress levels, fatigue damage, or excessive vibrations. By pinpointing these
areas, engineers can focus their efforts on implementing design modifications or improvements to
enhance the reliability and performance of the camshaft.
3. Determine Natural Frequencies and Mode Shapes: Modal analysis is an essential component of
random vibration analysis. The objective is to determine the camshaft's natural frequencies and
corresponding mode shapes. This information helps in understanding how the camshaft will
respond to different excitation frequencies and modes, aiding in the identification of potential
resonance issues and design optimization.
4. Evaluate Fatigue Life: Random vibrations can significantly impact the fatigue life of a camshaft.
An objective of the analysis is to assess the fatigue damage accumulation due to random
vibrations. By predicting the fatigue life of the camshaft, engineers can determine its expected
lifespan under realistic operating conditions and make informed decisions regarding maintenance
intervals or design improvements.
5. Optimize Design: The ultimate objective is to optimize the design of the camshaft to withstand
random vibrations and ensure reliable performance. Based on the analysis results, engineers can
propose design modifications such as material enhancements, geometrical optimizations, or the
addition of damping solutions to reduce stress levels, mitigate fatigue damage, and minimize
vibration levels.

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Chapter 2
Methodology
The analysis involved several steps, including data acquisition, signal processing, and finite element
analysis (FEA). The following outline summarizes the key procedures:

2.1 Data Acquisition:

Accelerometers were strategically placed on the camshaft to measure the vibrations experienced during its
operation. The data acquisition system recorded the vibrations in terms of acceleration over a specific
time period.

2.2 Signal Processing:

The raw acceleration data obtained from the sensors were processed to obtain the frequency content and
other relevant parameters. Techniques such as Fast Fourier Transform (FFT) and power spectral density
(PSD) were applied to analyze the data and identify the dominant vibration modes.

2.3 Finite Element Analysis (FEA):

A finite element model of the camshaft was developed using computer-aided design (CAD) software.
Material properties and boundary conditions were assigned to simulate the actual operating conditions.
The modal analysis was performed to determine the natural frequencies and mode shapes of the camshaft.
Additionally, random vibration analysis was conducted to evaluate the camshaft's response to random
excitation.

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Chapter 3
Results and Discussion
The results of the random vibration analysis provided insights into the camshaft's behavior under varying
operating conditions. Key findings include:
3.1 Natural Frequencies:
The modal analysis revealed the camshaft's natural frequencies and corresponding mode shapes. This
information is crucial for identifying potential resonant frequencies that could lead to excessive vibrations
and structural failures.

The following bar chart indicates the frequency at each calculated mode.

3.2 Frequency Response Function (FRF):

The frequency response function describes the camshaft's response to input vibrations at different
frequencies. It provides valuable information about the dynamic characteristics, including the
amplification or attenuation of vibrations at specific frequencies.

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3.3 Stress Analysis:
The random vibration analysis also enabled stress evaluation within the camshaft structure. Stress
concentrations, fatigue-prone regions, and potential failure points were identified. This information is
essential for optimizing the design and ensuring the camshaft's longevity.

Chapter 4
Conclusion
The random vibration analysis performed on the camshaft yielded valuable insights into its dynamic
behavior and structural integrity. The results identified critical frequencies, evaluated the camshaft's
response to random excitation, and provided stress analysis data. These findings can help engineers
enhance the design and manufacturing processes, leading to improved reliability and performance of
camshafts in various applications.

Recommendations
Based on the results obtained, the following recommendations are made:

 Consider optimizing the camshaft design to mitigate stress concentrations and reduce the risk of
fatigue failure.
 Conduct further analysis to evaluate the effects of different operating conditions, such as speed
and load variations.

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  Implement experimental validation to verify the accuracy of the finite element model and
simulation results.
 Explore the use of advanced materials and manufacturing techniques to enhance the camshaft's
durability and performance. By implementing these recommendations, it is expected that the
camshaft's reliability and performance can be significantly improved.

Chapter 5
References
1. Kolchin & V. Demidov, ‘Design of Automotive
2. Engines’, MIR Publication, Moscow.
3. Hansong Xiao and Jean W. Zu, Cam profile optimization for a new cam drive. Journal of
Mechanical Science and Technology, Department of Mechanical Engineering and
Industrial Engineering,
4. University of Toronto, vol. 23/2592-2602 (December 4, 2007)
5. K. Deb, Optimization for engineering design, an efficient constraint handling method for

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 genetic algorithms,
6. de Boor, Springer-Verlag, New York, USA, (1978), A Practical Guide to Splines.

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