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Presented By-S.K.Srivastava
Camshaft GearFor
ALCO Engine
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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
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Cam Gear location in Alco Engine
Cam Gearinside Cover
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Camshaft Gear
Use
To rotate camshaft.
Take power from crankshaft gear (Gear ratio 1:2).
2 nos. per loco.
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Camshaft Gear Data
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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
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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
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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
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Chuck, Finish OD, Co-bore - CNC VTL
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Drilling M/C for Lifting & Mounting Holes
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Lifting and mounting holes
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Teeth Cutting on gear Hobbing Machine
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Teeth Cutting on gear hobbing machine
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Gear profile grinding/Shaving
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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.
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STIFFER UNIT CAMSHAFT
Since 2003
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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
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FEATURES OF SUC
SIMPLICITYMAINTAINABILITYRELIABILITY
DURABILITYFUEL ECONOMY
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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
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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.
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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.
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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.
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Manufacturing related problemsProblems arises while manufacturing the backspot of 6 holes .
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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.
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Manufacturing process
of STIFFER UNIT CAM SHAFT
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TAKE ALLOY STEEL ROUND BAR OF160 DIA MM
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SAW CUT TO SIZE – 14 ” 32
9
14 ”
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FACE MILLING & CENTRE TO SIZE 14 ” 64
3
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FINISH TURN FLANGE, FACE, FLANGE GROOVE,NECK RADIUS, CO-BORE & FLANGE FACE RELIEF
- BOTH SIDE
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GUN DRILL SIZE ” HOLE THROUGH 4
3
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PUNCH NUMBRE FOR IDENTIFICATION
GRIND BOTH SIDE FACE TO
MAINTAIN TOTAL LENGTH
13.908-13.910 ”
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DRILL 01 NO. DAWEL/INDICATING
HOLE IN BOTH SIDE FLANGE
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SET ON JIG DIRLL 6 HOLE IN BOTHSIDE FLANGE DIA ”
32
17
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LOCATE FROM GEN. END, MILL 03NO. CAM PROFILE
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REMOVE SHARP EDGES BYROTARY
SEND TO HTS FOR HEATTREATMENT
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STRESS RELIEFHEAT THE JOB UPTO 450 0C & HOLD4 HOURS AT THIS TEMP. THEN COLLIN THE FURNACE AT ROOM TEMP.
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INDUCTION HARDENING OF ALL CAMJOB IS HEATED UPTO 820-840
0
C IN INDUCTIONFURNACE & POLYQUENCHING DONE -HARDING DEPTH 3-6 MM.
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TEMPERINGHEAT THE JOB UPTO 240 0 C & HOLD 4 HOURS. COOLIN FURNACE AT ROOM TEMP. 2-3 HOURS -HARDNES58-62 RC
SEND TO LMS
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CAM GRINDING ALL 03 LOBES AIR,EXHAUST & FUEL
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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