Cam Shaft Gear Presentation

8/4/2019 Cam Shaft Gear Presentation

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Presented By-S.K.Srivastava

Camshaft GearFor

ALCO Engine



Gears are commonly used to: -

Transmit power from one shaft to another.

To vary speed.

To convert rotary motion into translational and vice versa.

Use of Gear



Cam Gear location in Alco Engine

Cam Gearinside Cover



Camshaft Gear

Use

To rotate camshaft.

Take power from crankshaft gear (Gear ratio 1:2).

2 nos. per loco.



Camshaft Gear Data



Camshaft Gear DataType - Spur Gear

Teeth - InvolutesPitch Diameter - 26” OD - 26.460- 26.446” Nos. of teeth - 104

Diametrical Pitch - 4Pressure Angle - 20 Addendum - 0.2315” Thickness at PD - 0.3869- 0.3854” Indicated run out - 0.002” Lead error - 0.0005” Centre distance - 19.500” Taper bore - ¾” in diameter, 12” Taper



Cam Gear Material Specification

Material - Alloy Steel (Forge & Harden)Carbon Content - 0.43 to 0.48%

Manganese - 0.75 to 1.0%

Phosphorus - 0.04% maximum

Sulpher - 0.04% minimum

Silicon - 0.20 to 0.35%

Nickel - 0.40 to 0.70%

Chromium - 0.40 to 0.60%

Molybdenum - 0.15 to 0.25%

Hardness - 332 to 364 BHN



Machining ProcessChuck, Finish OD, Co-bore - CNC VTL

Reverse, Finish OD and Taper Bore - CNC VTL

Lifting & Mounting Holes

Teeth Cutting on gear hobbing machine.

Gear profile grinding/Shaving

Inspection

Broach Key Way

Locking hole

Burr removal

Number Punch

Despatch to HTS for Luborite



Chuck, Finish OD, Co-bore - CNC VTL





Drilling M/C for Lifting & Mounting Holes



Lifting and mounting holes



Teeth Cutting on gear Hobbing Machine



Teeth Cutting on gear hobbing machine



Gear profile grinding/Shaving



Lubrite Process in HTS

Lubrite is a rust preventive process.This Process is also known as phosphate Process.Solution of phosphoric acid ratio 1:10.Solution heated up to Temp-85-95 C.

After getting temp. is 85-95 C Camshaft Gear dipped insolution in one hour.After completion of lubrite process camshaft gear sent toENGINE ERECTION SHOP.2 Nos. camshaft gear used in per ALCO Engine.



STIFFER UNIT CAMSHAFT

Since 2003



Stiffer unit cam shaft is important part of the engine,which operate the engine valves (Air, Fuel & Exhaust)with better performance.

SUC plays an important role in engine up-gradation

1st Loco – 14962 (2003) upgrade engine 3300HP

INTRODUCTION



FEATURES OF SUC

SIMPLICITYMAINTAINABILITYRELIABILITY

DURABILITYFUEL ECONOMY



SIMPLICITYINTERCHANGABILITY

STIFFER UNIT CAMSHAFT -

SEGMENT POSSIBLE WITHIN LS (ALL SECTIONS) & SAMEWITHIN RS.

SPACER POSSIBLE (WITH SOME SPACERS) SAMELOCATION OF LS & RS.

CONVENTIONAL CAMSHAFT-

SECTIONS NOT POSSIBLE AT ALL



MAINTAINABILITY

One cam segment means for one cylinder andcan be attendant separatelyEach segment can be removed and replacedeasily whereas this removal is difficult in

conventional camshaft.



RELIABILITY & DURABILITY

Larger dia cam base circle & cam roller canwithstand higher stresses, resulting highercamshaft life and improve the self dampingcapacity.

Lever ratio of cross head 1:1 in comparisonto 1.3:1 and reduce the stress 30%Larger dia of lobes and roller also reducingcontact stresses.

More Stiffness of this camshaft provideresistance against the force of fuel pump andpush rod.27% Higher tortional stiffness.



FUEL ECONOMY

Improved Fuel cam profile reduce thelagging /delay in fuel injection.Better stiffness reduce the torsional & bending vibration and improve the fuel

efficiency after increasing fuel injectionpressure.Injection start at 22º before TDC instiffer unit camshaft reduce theinjection period.Higher fuel lift improve injectionpressure for fuel efficiency.



Manufacturing related problemsProblems arises while manufacturing the backspot of 6 holes .



Two designs were proposed – Proposal I - Stiff radius transferred on other side. Proposal II - Stiff radius removed and plane flange

with fillet radius provided.

Manufacturing related problemsTo overcome the problems arised while manufacturing the back spot

of 6 holes .

Finally proposal II adopted in drawing and production, resultingincrease in production and reduction in problem in assemblies.



Manufacturing process

of STIFFER UNIT CAM SHAFT



TAKE ALLOY STEEL ROUND BAR OF160 DIA MM



SAW CUT TO SIZE – 14 ” 32

9

14 ”



FACE MILLING & CENTRE TO SIZE 14 ” 64

3



FINISH TURN FLANGE, FACE, FLANGE GROOVE,NECK RADIUS, CO-BORE & FLANGE FACE RELIEF

- BOTH SIDE



GUN DRILL SIZE ” HOLE THROUGH 4

3



PUNCH NUMBRE FOR IDENTIFICATION

GRIND BOTH SIDE FACE TO

MAINTAIN TOTAL LENGTH

13.908-13.910 ”



DRILL 01 NO. DAWEL/INDICATING

HOLE IN BOTH SIDE FLANGE



SET ON JIG DIRLL 6 HOLE IN BOTHSIDE FLANGE DIA ”

32

17



LOCATE FROM GEN. END, MILL 03NO. CAM PROFILE



REMOVE SHARP EDGES BYROTARY

SEND TO HTS FOR HEATTREATMENT



STRESS RELIEFHEAT THE JOB UPTO 450 0C & HOLD4 HOURS AT THIS TEMP. THEN COLLIN THE FURNACE AT ROOM TEMP.



INDUCTION HARDENING OF ALL CAMJOB IS HEATED UPTO 820-840

0

C IN INDUCTIONFURNACE & POLYQUENCHING DONE -HARDING DEPTH 3-6 MM.





TEMPERINGHEAT THE JOB UPTO 240 0 C & HOLD 4 HOURS. COOLIN FURNACE AT ROOM TEMP. 2-3 HOURS -HARDNES58-62 RC

SEND TO LMS



CAM GRINDING ALL 03 LOBES AIR,EXHAUST & FUEL



REMOVE BURRS FROM ALL CAM

EDGESMAGNAFLUX TEST & DE-MAGNETISEBUFING ON OPENING FLANK OF

FUEL CAMFINAL INSPECTION & HARDEN TESTAPPLY RUST PREVENTIVE

SEND TO SUB ASSEMBLE SHOP



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Cam Shaft Gear Presentation