Camshaft

A camshaft is a mechanical device used in an IC engine to perform the opening and closing action of the inlet and exhaust valve
at the right time. The basic function is to convert rotatory motion into linear motion.
As we know that in an internal combustion engine it is very important that the fuel should come into the cylinder at the right time
and the exhaust gases should also leave the cylinder at the right moment of time. This function is accomplished with the help of a
camshaft. A camshaft achieves its motion either independently or by the engine crankshaft.

The function of camshaft:

The following three functions are:
1. It promotes the opening of the inlet valve during the suction stroke.
2. The second function is to open the exhaust valve during the exhaust stroke.
3. Lastly, it keeps both the valves closed the rest of the time.
Construction of Camshaft:
The main parts involved in the construction of the camshaft are:
 Driveshaft
 Shaft
 Bearings
 Cam
 Lobes
 Thrust plate
 Chain sprocket and
 Woodruff key

Driveshaft:
This is the part of the camshaft that provides motion to the whole assembly is called a drive shaft. A drive shaft is either
connected to the crankshaft with a belt or is operated independently. In most cases, it is connected with the crankshaft.
Shaft:
The supporting structure which holds all the other components is called a shaft. It is designed to withstand high fatigue loads
when the engine is running.
Bearings:
Bearings are very important elements of it as it holds the shaft in the correct position and also reduces frictional losses during the
operation of the camshaft. It is also provided with an oil inlet for a constant oil change in the camshaft.
Cam:
Cams are the main parts of the assembly. A cam is so designed that it keeps the valves closed all the time and opens it by pushing
it at the right moment. A cam and follower set are discussed later in the article.
Lobes:
The main working of lobes is to open and close the valves for intake and exhaust gases. The speed of the lobe depends on the
current engine speed.
Thrust plate:
As you can see in the diagram The thrust plate is on the right side and it is attached between the cam and timing gear. The thrust
plate is mounted on the front cover for proper end play.
Chain sprocket:
It is attached to one end of the camshaft in a combustion engine. This sprocket, along with the timing belt and the crankshaft
sprocket, is responsible for maintaining the timing between camshaft and crankshaft.
Working of camshaft:
Before understanding the working of the camshaft, it is necessary to understand the working of cam and follower arrangement
which is also the principle behind the working of automobile camshaft.
Working principle:

The figure shows different stages of cam and follower. The cam is not circular in shape hence when rotated it lifts the follower up
and down. In diagram one, the peak of the cam has lifted the follower to the fullest. As the cam rotates in an anticlockwise
direction the follower drops down a then again starts rising after the cam has moved by 180 degrees.

Working of the camshaft in an IC engine

The figure shows the actual operation of a camshaft in an internal combustion engine. The valve is closed in figure 1. As the cam
rotates due to the rotation of the drive wheel, it pushes the valve against the spring and thus opening the valve in the next figure.
As soon as the operation (fuel inlet or exhaust gas outlet) is done the spring forces the valve back to its original closed position.

How does Camshaft work?

The camshaft is operated by the crankshaft either by a pair of meshing gears (timing gears) or a pair of timing sprockets
connected by chains. The camshaft gear or sprocket has as many teeth as the gear or sprocket on the crankshaft.

This gives a 1:2 gear ratio. The camshaft rotates at half the speed of the crankshaft. Therefore every two revolutions of the
crankshaft create one revolution of the camshaft and one opening and closing of each valve in the four-cylinder engine.
The gear and sprocket maintain a definite time relationship between the camshaft and crankshaft to insure opening the valves
exactly at the correct time in relation to piston position.

Timing marks on the gears and sprockets are used to set the shaft incorrect times with each other when the units are assembled.
The figure shows that the smaller circle on the crankshaft timing gear must fall between the two smaller circles on the crankshaft
timing gear to ensure correct valve timing. The sprocket marks are in a straight line with the centers of both shafts to ensure
correct valve timing.

Types of camshafts:
There are two types of camshafts:
1. Single overhead and
2. Double overhead camshaft.

Single overhead camshaft:

A single overhead camshaft is often referred to as SOHC. As the name suggests a single overhead uses only one shaft with
multiple cams to operate input and exhaust valves.
In the case of SOHC, there is a need to use a rocker arm to perform the opening and closing of the valves.
It was an earlier designed camshaft. It provides better torque at mid-RPM.
Simple design leads to ease of understanding. There is a place for the spark plug to be placed as the camshaft is placed in between
the two cylinders.

Double overhead camshaft:

A double overhead camshaft is also commonly known as DOHC. This uses two separate shafts with cams to operate exhaust and
inlet valves.
A rocker arm is not needed in a double overhead. This is an advanced version of a single overhead..
It helps the engine to obtain high RPM. The design of a double overhead is complex. There is no difficulty to locate the spark
plug in the DOHC.

Comparison between the Single and Double overhead camshaft:

Advantages of Double Overhead over Single Overhead Camshaft are:
 There are twice the number of valves in DOHC than SOHC which leads to better performance and results in increased
airflow and low noise.
 A better valve timing can be obtained by DHOC than SHOC. As we know valve timing can have serious effects on the
engine performance since in SOHC only one camshaft operates both the valves the valve timing is disturbed.
 In DOHC the location of the spark plug is easier than in SOHC due to the fact that the camshaft can be placed at
various angles which allows space to locate the spark plug on the top of the cylinder.
 The top performance of a double overhead is quite more than that of a single overhead.
Advantages of SOHC over DOHC:
 One of the major advantages of a single overhead over a double overhead camshaft is cost. The cost of SOHC is lower
than that of DOHC also the maintenance cost is also low.
 It is difficult to repair a double overhead camshaft in case of any failure due to the large number of parts involved.
 The weight of a single overhead is also less than the double overhead camshaft. A lower weight is always desirable.
 The initial torque in the case of SOHC is higher than that of DOHC.

Material used for making Camshaft:

When it comes to the manufacturing of camshaft, there are mainly two materials are being used which are Iron and Steel. The
Iron material is used for high volume production and Steel is used for low volume production and high-quality camshafts.
The camshaft is used for high rigidity, therefore cast-iron material is used as it offers great strength. Some other materials are also
being added to Iron before casting.
This is manufacture by the Forging or casting process and further, it is machined by a Lathe machine.

Reason for Failure of Camshaft:

It is a very important part of an engine. When it gets damaged, it can create failure of an engine. Let see what may be a possible
cause for the failure of the camshaft:
 Damage of cam of the Camshaft.
 Incorrect valve spring pressure.
 Improper break-in.
 The problem with the lob wear because of not proper lubricant. and so on.

Difference between Camshaft and Crankshaft:

Camshaft Crankshaft
It is used for closing and opening of engine valve The crankshaft is used to convert the reciprocating or oscillation motion of
for the right timing. the piston into the rotary motion.
It is attached to a crankshaft and rotated by a
The crankshaft is being rotated with the help of a Piston.
timing belt.
This is located at the top of the cylinder head. It is located bottom of the cylinder head.
It can be made with two metals Iron or steel. Crankshafts are made with alloy steel.
Camshaft vs Crankshaft
Advantages of camshaft:
The following advantages are:
 Camshaft enables proper inflow and outflow of fuel and exhaust gases respectively.
 The design is quite simple.
 It is durable and easy to maintain.
 Provides smooth operation even at high speed.
 A single camshaft can be used for many cylinders.
Disadvantages of camshaft:
The following disadvantages are:
 Overheating problems are usual with camshafts.
 A broken camshaft may cause serious damage to the engine.
 The cost of it is costly.
Applications of camshaft:
 The main application of camshaft is in internal combustion engines.
 Camshafts with gears were also used to operate oil pumps.
 It is also used wherever there is a need to convert Rotary motion to linear motion.

Arrangement of cylinders can be very various.

Generally used arrangements are:
- in line arrangement
- V arrangement
- opposed cylinder engine
- radial type engine

Wankel rotary engine

In order to reduce engine components and produce more compact engine, and to reduce losses which caused by alternating
movements in traditional engine, an engine with rotary piston (or pistons) were invented which is called Wankel engine. But now
it is not used because its sealing and leakage problems. There are two rotating parts, the triangular-shaped rotor and the output
shaft with its integral eccentric. The rotor revolves directly on the eccentric. The rotor has an integral timing gear which meshes
with the fixed timing gear on one side housing to maintain the correct phase relationship between the rotor and eccentric shaft
rotations. Thus, the rotor rotates and orbits around the shaft axis. Breathing is through ports in the center housing. The
combustion chamber lies between the center housing and rotor surface and is sealed by seals at the apex of the rotor and around
the perimeters of the rotor sides. Wankel rotary engine operates with four stroke cycle. As the rotor makes one complete rotation,
during which the eccentric shaft rotates through three revolutions, each chamber produces one power stroke. Three power pulses
occur, therefore, for each rotor revolution; thus, for each eccentric (output) shaft revolution there is one power pulse.

Four stroke diesel engine

The cycle of operation in a four stroke diesel engine is completed in two revolutions of crankshaft or four strokes of piston using
diesel oil as fuel. This engine works on diesel cycle.
1. Intake Stroke:
Starting of engine is done by an electric motor or manually. In both cases the energy is supplied to the engine. In this stroke the
inlet valve opens and the outlet valve remains closed. Piston moves from T.D.C. to B.D.C. and in this way a vacuum is created in
the cylinder. This vacuum is filled by air alone and piston reaches to B.D.C.
2. Compression Stroke:
Both valves are closed. This time piston moves from B.D.C. to T.D.C. Air is compressed in this stroke up to a compression ratio
of 15:1 to 22:1 and a very high temperature is produced due to high pressure. The high temperature is the only cause of
combustion of the fuel. The piston takes the power in this stroke from the flywheel. During this stroke the pressure and
temperature attain a high value of 40 to 60 bar and 600º C to 700º C.
3. Power Stroke:
At the end of compression stroke or when the piston reaches the T.D.C. position, a fine spray of diesel is injected in the cylinder
through injector. The fuel burns by the heat of compressed air and due to its burning the power is produced. This power pushes
the piston downward i.e. from T.D.C. to B.D.C. The excess energy of the piston is stored in the flywheel of the engine, which is
further used for the remaining three strokes of the engine. The reciprocating motion of the piston is converted into the rotary
motion of the crankshaft by connecting rod and crank. During expansion the pressure drops due to increase in volume of gases
and absorption of heat by cylinder walls.
4. Exhaust Stroke:
The exhaust valve begins to open when about 85% of the working stroke is completed. The force of piston coming from B.D.C.
to T.D.C. forces the burnt gases into the exhaust manifold. Some of the gases are forced out due to higher pressure in the cylinder
and the remaining gases are forced out by the piston. Some of the burnt gases are however left inside the clearance space. The
exhaust valve closes shortly after T.D.C. The inlet valve opens slightly before the end of exhaust and in this way the cycle
repeats.

Two stroke diesel engines.

A two-stroke diesel engine is a diesel engine that works in two strokes. All diesel engines use
compression ignition, a process by which fuel is injected after the air is compressed in the
combustion chamber, thereby causing the fuel to self-ignite.
The two stroke engine employs both the crankcase and the cylinder to achieve all the elements of
the Otto cycle in only two strokes of the piston.
Intake. ...
Crankcase compression. ...
Transfer/Exhaust. ...
Compression. ...
Power.

The two-stroke diesel cycle is as follows:

1. When the piston is at the top of its travel, the cylinder contains a charge of highly
compressed air. Diesel fuel is sprayed into the cylinder by the injector and immediately
ignites because of the heat and pressure inside the cylinder.
2. The pressure created by the combustion of the fuel drives the piston downward. This
is the power stroke.
3. As the piston nears the bottom of its stroke, all of the exhaust valves open. Exhaust
gases rush out of the cylinder, relieving the pressure.
4. As the piston bottoms out, it uncovers the air intake ports. Pressurized air fills the
cylinder, forcing out the remainder of the exhaust gases.
5. The exhaust valves close and the piston starts traveling back upward, re-covering the
intake ports and compressing the fresh charge of air. This is the compression stroke.
5. As the piston nears the top of the cylinder, the cycle repeats with step 1.