Camshaft Gear For ALCO Engine

Presented ByS.K.Srivastava

Use of Gear

Gears are commonly used to: Transmit power from one shaft to another. To vary speed. To convert rotary motion into translational and vice versa.

Cam Gear location in Alco Engine

Cam Gear inside 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 Data

Type Teeth Pitch Diameter OD Nos. of teeth Diametrical Pitch Pressure Angle Addendum Thickness at PD Indicated run out Lead error Centre distance Taper bore Spur Gear Involutes 26 26.460-26.446 104 4 20 0.2315 0.3869-0.3854 0.002 0.0005 19.500 in diameter, 12 Taper

Cam Gear Material Specification

Material Carbon Content Manganese Phosphorus Sulpher Alloy Steel (Forge & Harden) 0.43 to 0.48% 0.75 to 1.0% 0.04% maximum 0.04% minimum

Silicon
Nickel Chromium Molybdenum Hardness

0.20 to 0.35%
0.40 to 0.70% 0.40 to 0.60% 0.15 to 0.25% 332 to 364 BHN

Machining Process
Chuck, 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-85-95C. After getting temp. is 85-95C Camshaft Gear dipped in solution in one hour. After completion of lubrite process camshaft gear sent to ENGINE ERECTION SHOP. 2 Nos. camshaft gear used in per ALCO Engine.

STIFFER UNIT CAMSHAFT

Since 2003

INTRODUCTION
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

FEATURES OF SUC
SIMPLICITY MAINTAINABILITY RELIABILITY DURABILITY FUEL ECONOMY

SIMPLICITY
INTERCHANGABILITY
STIFFER UNIT CAMSHAFT SEGMENT SPACER POSSIBLE WITHIN LS (ALL SECTIONS) & SAME WITHIN RS. POSSIBLE (WITH SOME SPACERS) SAME LOCATION OF LS & RS.

CONVENTIONAL CAMSHAFTSECTIONS NOT POSSIBLE AT ALL

MAINTAINABILITY
One cam segment means for one cylinder and can be attendant separately Each segment can be removed and replaced easily whereas this removal is difficult in conventional camshaft.

RELIABILITY & DURABILITY

Larger dia cam base circle & cam roller can withstand higher stresses, resulting higher camshaft life and improve the self damping capacity. Lever ratio of cross head 1:1 in comparison to 1.3:1 and reduce the stress 30% Larger dia of lobes and roller also reducing contact stresses. More Stiffness of this camshaft provide resistance against the force of fuel pump and push rod. 27% Higher tortional stiffness.

FUEL ECONOMY
Improved Fuel cam profile reduce the lagging /delay in fuel injection. Better stiffness reduce the torsional & bending vibration and improve the fuel efficiency after increasing fuel injection pressure. Injection start at 22 before TDC in stiffer unit camshaft reduce the injection period. Higher fuel lift improve injection pressure for fuel efficiency.

Manufacturing related problems

Problems arises while manufacturing the back spot of 6 holes.

Manufacturing related problems

To overcome the problems arised while manufacturing the back spot 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.

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

Manufacturing process of
STIFFER UNIT CAM SHAFT

 TAKE ALLOY STEEL ROUND BAR OF 160 DIA MM

 SAW CUT TO SIZE

9 14 32

14

3 FACE MILLING & CENTRE TO SIZE 14 64

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

 GUN DRILL SIZE

3 4

HOLE THROUGH

 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 BOTH 17 SIDE FLANGE DIA

32

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

 REMOVE SHARP EDGES BY ROTARY

SEND TO HTS FOR HEAT TREATMENT

 STRESS RELIEF
HEAT THE JOB UPTO 4500C & HOLD 4 HOURS AT THIS TEMP. THEN COLL IN THE FURNACE AT ROOM TEMP.

 INDUCTION HARDENING OF ALL CAM

JOB IS HEATED UPTO 820-8400C IN INDUCTION FURNACE & POLYQUENCHING DONE
HARDING DEPTH 3-6 MM.

 TEMPERING
HEAT THE JOB UPTO 2400C & HOLD 4 HOURS. COOL IN 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 EDGES MAGNAFLUX TEST & DE-MAGNETISE BUFING ON OPENING FLANK OF FUEL CAM FINAL INSPECTION & HARDEN TEST APPLY RUST PREVENTIVE
SEND TO SUB ASSEMBLE SHOP

Thanks For Your Attention