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Cam Roller Contact: The topographical aspect
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces. (Functional Surfaces Research Group)ORCID iD: 0000-0002-9447-9635
2008 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The automotive industry and the design of engines are strongly ruled by performance and legislation demands. First order aspects defining the main functions of a component are well known and new challenges appear at a lower scale. Wear reduction is defined as a second order problem and requires decreasing the scale of observation of components down to roughness. This thesis work and its aim lie within the scope of wear improvements and are focused on the injection cam/roller contact of heavy duty diesel engines. In order to reach the aim several material and methods are used: a valve train rig test, roughness characterisation and different manufacturing processes. It is shown by experiments that the flank and nose of injection cams are specific areas with specific roughness (higher density of summits Sds) compared to the rest of the cam. The wear is characterized by rounded-off of summits (Ssc). From those results and since wear processes are strongly linked to the pressure generated between the mating surfaces, the development of a rough contact model is of great interest. An elastic rough contact model is implemented and improved later on by an elasto-plastic description of materials. The simulations are validated by a wear test and are used to rank the ability of surfaces (both cam and roller) to face wear problems. The ratio of plastically deformed peaks shows that the flank and nose of the cam are reacting badly to pressures. Additionally the rough contact allows ranking/optimization of different machining processes with respect to their expected functional contact performance. Future work will be to use such a model to choose a good combination of surfaces (cam and roller) in order to reduce wear.

Place, publisher, year, edition, pages
Göteborg: Chalmers University of Technology , 2008. , p. 62
Series
Technical report / Department of Materials and Manufacturing Technology, Chalmers University of Technology, ISSN 1652-8891 ; 40
Keywords [en]
injection cam, roller, surface topography, rough contact model, wear test, classification of surfaces, manufacturing evaluation
National Category
Manufacturing, Surface and Joining Technology
Identifiers
URN: urn:nbn:se:hh:diva-6136OAI: oai:DiVA.org:hh-6136DiVA, id: diva2:357199
Presentation
2008-12-05, Delta-Gamma, Hörsalsvägen 7 Chalmers, Göteborg, 13:30 (English)
Opponent
Supervisors
Projects
Contact mechanics of the cam follower systemAvailable from: 2011-03-29 Created: 2010-10-15 Last updated: 2015-02-18Bibliographically approved
List of papers
1. The evolution of surface topography of injection cams
Open this publication in new window or tab >>The evolution of surface topography of injection cams
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2009 (English)In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 266, no 5-6, p. 570-573Article in journal (Refereed) Published
Place, publisher, year, edition, pages
Amsterdam: Elsevier, 2009
Keywords
injection cam, wear, surface topography, interferometer, replicas
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-6137 (URN)10.1016/j.wear.2008.04.057 (DOI)000264568600020 ()2-s2.0-60449107293 (Scopus ID)
Available from: 2010-10-15 Created: 2010-10-15 Last updated: 2017-12-12Bibliographically approved
2. Tribological aspect of the surface topography variations for injection cams
Open this publication in new window or tab >>Tribological aspect of the surface topography variations for injection cams
2008 (English)In: Proceedings of the NORDTRIB 2008 / [ed] Jaakko Kleemola and Arto Lehtovaara, Tampere: Tampere University Press, 2008, , p. 16Conference paper, Published paper (Refereed)
Place, publisher, year, edition, pages
Tampere: Tampere University Press, 2008. p. 16
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-6138 (URN)978-952-15-1959-8 (ISBN)
Conference
13th Nordic symposium on Tribology, Tampere, Finland, 10-13 June, 2008
Available from: 2010-10-15 Created: 2010-10-15 Last updated: 2015-02-18Bibliographically approved
3. Evaluation of cam and roller surfaces and their manufacturing process by functional characterization
Open this publication in new window or tab >>Evaluation of cam and roller surfaces and their manufacturing process by functional characterization
2008 (English)In: Proceedings of the Swedish Production Symposium 2008, Stockholm: Swedish production symposium , 2008, , p. 7Conference paper, Published paper (Refereed)
Place, publisher, year, edition, pages
Stockholm: Swedish production symposium, 2008. p. 7
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-6139 (URN)
Conference
The Swedish Production Symposium 2008 (SPS'08), Nacka Strand, Stockholm, 18 november, 2008
Available from: 2010-10-15 Created: 2010-10-15 Last updated: 2015-02-18Bibliographically approved
4. Evaluation of cam surfaces by wear testing and functional characterization
Open this publication in new window or tab >>Evaluation of cam surfaces by wear testing and functional characterization
2008 (English)In: Synopses / 35th Leeds-Lyon Symposium on Tribology, Leeds: Leeds University , 2008Conference paper, Published paper (Other academic)
Abstract [en]

Friction and wear are constant problems encountered in camshaft development. The contact between roller and cam is a mix of sliding and rolling which leads to a wide range of failure modes. The uniqueness of this contact is also due to variations all around the cam of a multitude of parameters such as load and radius. A previous study described surface topography as a function of cam shape. The different types of wear mechanisms are strongly linked to contact pressures which are also dependent on roughness. The aim of the paper is to develop a rough contact model which will be utilized as a tool to rank surfaces and their ability to face wear problems. In order to verify the tool, rough contact results are compared to roughness parameter variations due to wear produced in a cam roller rig test. The surface measurements used for this study are made by a non-contact light interferometer. The Greenwood-Williamson contact model has been developed in a deterministic way and the elasto-plastic behaviour of the material has been integrated to the model. The outputs of the simulation give a ranking of surfaces which is compared to their roughness variations due to wear. The study shows that the model developed is a reliable tool to rank and define surface quality since the results are correlated to wear. However, the results show as well some discrepancies which could be corrected in the future by integrating to the model two new features: a rough to rough contact including sliding between surfaces. This new model should be verified by an accurate experimentation using relocation between unworn and worn surfaces.

Place, publisher, year, edition, pages
Leeds: Leeds University, 2008
Keywords
injection cam, wear, elasto-plastic rough contact, surface quality
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-6140 (URN)
Conference
35th Leeds-Lyon Symposium on Tribology
Available from: 2010-10-15 Created: 2010-10-15 Last updated: 2015-02-18Bibliographically approved

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