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19A503 - Vehicle System Design

The valve spring provides a force on the rocker arm to maintain contact between the follower and cam. During the intake stroke, the initial spring force keeps the valve closed against negative pressure. The total force on the exhaust valve spring consists of the initial spring force and the force needed to lift the valve. The document then provides steps to calculate the design of a valve spring for a four-stroke engine using given data and formulas for wire diameter, mean coil diameter, number of turns, compression, length, and pitch of coils. A tappet helps command valve movement by limiting the gap between the camshaft and valves, which is essential for proper air/fuel mixing and combustion. Tappets also eliminate the need for adjustments

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mugesh oo7
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27 views27 pages

19A503 - Vehicle System Design

The valve spring provides a force on the rocker arm to maintain contact between the follower and cam. During the intake stroke, the initial spring force keeps the valve closed against negative pressure. The total force on the exhaust valve spring consists of the initial spring force and the force needed to lift the valve. The document then provides steps to calculate the design of a valve spring for a four-stroke engine using given data and formulas for wire diameter, mean coil diameter, number of turns, compression, length, and pitch of coils. A tappet helps command valve movement by limiting the gap between the camshaft and valves, which is essential for proper air/fuel mixing and combustion. Tappets also eliminate the need for adjustments

Uploaded by

mugesh oo7
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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TOPIC: design of valve spring

and tappet valve


DESIGN OF VALVE SPRING
• The purpose of the valve spring is to exert a
force on the rocker arm in order to maintain
contact between the follower and cam at the
other end.
• During the suction stroke, the initial spring
force keeps the valve closed against negative
pressure inside the cylinder.
• The total force acting on the spring of the
exhaust valve consists of two factors, viz., the
initial spring force and force required to lift
the valve.
The initial spring force is given by
Pi = area of valve * maximum suction pressure

where, ps = maximum suction pressure (MPa)


The force required to lift the valve (P2) is given
by,
where,
k = stiffness of spring (N/mm)
δ =maximum lift of valve (mm)
Adding (a) and (b), the maximum force on spring
(Pmax.) is given by
THE FOLLOWING ASSUMPTION ARE MADE
IN THE VALVE SPRING
• The spring is made of oil-hardened and
tempered valve spring wire of Grade-VW.
• The stiffness of the spring is 10 N/mm.
• The allowable torsional shear stress for spring
material is 250 to 350 N/mm2.
• The spring index (D/d) is 8.
• The spring has square and ground ends.
THE DIMENSIONS OF THE SPRING ARE
CALCULATED BY THE FOLLOWING STEPS:
Step 1:
• Wire diameter

• where,
• t = allowable torsional shear stress (250 to
• 350 N/mm2)
• C = spring index (8)
• d = wire diameter (mm)
• K = Wahl factor
• K=(4C - 1/4C - 4) + (0.615/C)
Step 2:
Mean coil diameter:
D=Cd
where,
D = mean coil diameter (mm)
Step 3:
Number of active turns:
• where,
• N = number of active turns
• G = modulus of rigidity (84 * 10^3 N/mm^2)
• k = stiffness of spring (10 N/mm)
Step 4:
Total Number of Turns For square and ground
ends:
Nt = N + 2
where,
Nt = total number of turns.
Step 5:
Maximum Compression of Spring

where,
δmax. = maximum compression of spring (mm).
Step 6:
Solid Length of Spring
Solid length = Nt*d.
Step 7:
Free Length of Spring
There should be a gap between consecutive coils
when the spring is subjected to maximum force
(Pmax). The total gap is assumed as 15% of the
maximum compression.
Total gap = 0.15 δmax.
Free length = solid length + δmax. + 0.15 δmax.
Step 8:
Pitch of coils
Pitch of coils = free length/(nt - 1).
Problem 1
Design a valve spring for the exhaust valve of a four-stroke
engine using the following data:
Diameter of valve head = 75 mm
Lift of valve = 25 mm
Maximum suction pressure = 0.02 MPa below atmosphere
Stiffness of spring = 10 N/mm
Spring index = 8
Permissible torsional shear stress for spring wire = 300 N/mm2
Modulus of rigidity = 84 *10^3 N/mm2
Total gap between consecutive coils, when the spring is
subjected to maximum force, can be taken as 15% of the
maximum compression.
Given:
dv = 75 mm
ps = 0.02 MPa = 0.02 N/mm^2
h = 25 mm
k = 10 N/mm
C=8
= 300 N/mm^2
G = 84 * 10^3 N/mm^2
• Step I
Maximum force on spring The initial spring force
Pi is given by,

The maximum force on spring (Pmax) is given by,


Pmax. = Pi + kδ = 88.36 + 10 (25) = 338.36 N
(δ=h).
Step II
Wire diameter:
The Wahl factor is given by
K=(4C - 1/4C - 4) + (0.615/C)
K=(4(8)- 1/4(8) - 4) + (0.615/8)
K=1.184

d = 5.22 or 6mm.
Step III
Mean coil diameter:
D = Cd = 8(6) = 48 mm.
Step IV
Number of active turns
Step V
Total number of turns:
For square and ground ends
Nt = N + 2 = 13 + 2 =15
Step VI
Maximum compression of spring:
Step VII
Solid length of spring:
Solid length = Nt*d = 15(6) = 90 mm.
Step VIII
Free length of spring:
Free length = solid length + δmax + 0.15δmax.
= 90 + 35.75 + 0.15 (35.75)
= 131.11 mm.
Step IX
Pitch of coils:
Pitch of coils =
TAPPET VALVE
• the valve tappet is a very small part that helps
the camshaft on its function of opening the
intake and pressure relief valves of the engine.
FUNCTION OF TAPPET
• The function of the tappet is to close the
clearance between the camshaft and the
rocker arm, eliminating the necessity for
adjustments of the component, as well as
other adjustments in amplitude, which when
not aligned and positioned correctly may
harm engine performance.
PURPOSE OF TAPPET
• A tappet is responsible for helping command
the movement of the engine valves by limiting
the gap between the camshaft and the valves
helping with the internal combustion process.
• Tappets are therefore essential to the timely
mixture of air and fuel and thus combustion.
ADVANTAGES OF TAPPET
• As the whole process is actuated by hydraulic
pressure at engine start, there is no need for
service or adjustment. Another advantage is
cheaper operation, as there is no need for
service and charges associated with tappet
maintenance.
Thank you

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