UNIT III

Valve Actuating Mechanism

Design of valve
Main formula

Abbreviation

Assume value

Material Selection
Step-1

Size of the valve port:

v pa p = a*v

vp

= Men Velocity Of Gas

flowing through the port (m/s)

ap

=Area Of The Valve Port

Assume

(m/s)

Low speed ( inlet valve =33 to 40

Exhaust valve =40 to 50)

a = Area of the piston

v = Velocity of the piston

v
( p)

High speed( inlet valve =80 to 90

Exhaust valve=90 to 100)

Step-2
Thickness of the Valve

t=K

K=0.54( Cast iron)

K= constant

p=
d

K=0.42 ( Steel)
Diameter of the port(mm)

p
b

P= Maximum pressure (N/

mm

b= (Alloy Steel = 100 to 120

Carbon Steel = 50 to 60)

= Bending stress (N/

mm2 )
Step-3
Maximum Lift of the valve

h = maximum lift of the valve

= Valve Tapper

30
=(45) in degree

dp

h= 4 cos

In case of the flat headed valve

20

=0

Step-4
Steam Diameter (
=

dp

ds

/8 + 6.35 to

dp

)
/8 + 11

mm
Step-5
D= Diameter of the piston
Area of the piston

a= 4

Step-6
Velocity of the piston

V=

2 ln
60

m/s

Step-7
Width of valve seat
0.05dp to 0.07dp
Valve head diameter
dv = dp+2*width of valve seat

Design of valve spring

Step-1
Material of the Wall

21

Step-2

W=Total loading in spring

Mean Diameter of the Spring Coil

C=Spring Index

= K*

8 wC
2
d

d=Diameter
C=5or6

( 4 C1)
K= (4 C4)

0.615
C

=shear stress in (N/ mm

D 0 =Outer Diameter

D
C= d

D= Diameter of Standard Size

D=C*d
D0 = D+d
D=

Di +d

Step-3

n= No of turns of coil

Number of Coil

w=Total load (N)

8 wC 3 n
Gd

(N/ mm

c=Spring Index
)

G =Modulus of rigidity (N/

2

n=n+2

mm

Step-4

= max( deflection)

Free Length of the Spring

Lf = nd+

max

+0.15

max

22

Step-5
Pitch of the coil(P)
P=free length/(n-1)

Valve Spring Using Twisting Moment

Step-1
Valve Spring Material
Step-2

D=Mean Diameter

Mean Diameter of the Spring Coil

8 wC
= K* d 2

( 4 C1)
K= (4 C4)

D=

Di =Inside Diameter
d=Diameter of the spring wire

0.615
C

W=valve open(N)

Di +d

Maximum Twisting Moment of

Spring
W1*D/2= /16

3
* D

D
C= d
D0 = D+d
D=

Di +d

23

G =84(N/ mm2 )

Step-3
Number of Turns

8 wC 3 n
=
Gd

1
=
w 8
2

(N/ mm

W=W1-W2(N)
n=n+2

Step-4
Free Length of the Spring

Lf = nd+ max+0.15
max

max=

w 1w 2 mm

max=

h
w 1w 2 mm

Step-5
Pitch of the coil(P)
P=free length/(n-1)

Design of Tappet
d c = Core Diameter of the

Step-1

tappet(mm)

The load on Tappet

d
2

Fe=
/4* ( c ) * c

c =Permissible Compressive
(N)

Stress

24

c =50 (N/ mm2 )

Step-2
Diameter of the Tappet
d=

d c /0.84 mm

Step-3
Depth of the Tappet
t = 2*

d c mm

Design of cam
Step-1
Diameter of the Cam shaft(D)
D= 0.16*Cylinder bore+12.7 in mm
Step-2
Base Circle
=D+3 in mm
Step-3

b sc =Width of the Cam

Width of the Cam

= Width of the Roller

b sc = 0.09* cylinder
bore+0.6+0.11*cylinder bore+12
mm
Step-4
Prime Circle
= Minimum Radius of Cam(d)
+1/2Diameter of the Roller mm

Design of Rocker & Rocker Shaft

25

Step-1
Find the Gas Load

d
2
p
P1= /4* ( v ) * c in N

d v = d p +2*0.05* d p in
mm

P1=Gas Load in N

d v = Diameter of the valve in

mm

pc = Pressure in (N/ mm2 )

d p= Diameter of the piston in
mm

a p * v p =a.v

ap

d
2

=
/4* ( p)

Step-2

M= Mass of valve

Weightt of the Associated part

G=Gravity

W= m*g

A=

/4* D 2

Step-3

W= weight

Total Load of the

P=Gas load in N

P= P1+w
Step-4
Spring Force (Fs)

d
2
p
Fs= /4* ( v ) * s -w in

N
Step-5
Force due to Acceleration (Fa)
Fa=

mv *a+w

a=acceleration

=2 /T

T=

26

g= 9.81

Angle of action of cam

angleof turned by camshaft

2
a= r

Angle of Turned by Camshaft

speed of the cam shaft
=
*360
60

2
S=ut+1/2a t

Speed of the cam shaft

speed
=
2
r=h/2

Step-6

P=Gas load in N

The Total on the Exhaust Valve

Fa=Acceleration Force in N

Fe = P+Fa+Fs

Fs=Sring Force in N

= Angle in fulcuram Pin

Step-7
Reaction of the Fulcuram Pin
2

d1=Diameter of pin in mm

F= ( Fe + Fc 2 FeFc cos )
R
F= d 1l1pb
R

l1 = Length of the pin in mm

Pb= bearing pressure in (N/

mm2 )

Design Of Fulcrum Pin

Step-1
The Load of the Fulcrum Pin

d1=Diameter of the fulcrum pin in

mm
l1= length of the fulcrum pin in mm

Pb=3.5 to 6 N/ mm
l1=1.25d1

F=
R d1+l1+pb

27

Step-2

RF =

=Shear Stress in N/ mm

2
4 d1

External diameter of the boss

D1=2d1
Internal diameter of the hole in the
lever
dh=d1+2*3
Step-3
Bending Moment
M= Fe*l in N.mm
Section modulus (Z)
Z=

1
3
3
l 1( D 1 d h )
12
D1
2

P.S.G DATA BOOK 6.1

(Or)

bh3h 1 b3
Z=b/6*
h

Design of Fork End

Step-1
Design of Fork End

Fc=d 2l 2Pb

d2=Diameter of Roller pin in mm

Pb=7 N/ mm

l2 = Length of the roller pin

= 1.25 d1
2

Pb= Bearing pressure in (N/ mm

Fe=Fc
FC =

2
4 d2

Step-2
Thickness
t2=l2/2

28

Step-3
Maximum Bending Moment

Fc=design of fork end in N

M=Moment in N.mm
3
Z=Section modulus in mm

b =M/Z
5
M= 24 *Fc*l2

Z= 32 * d 2

t2
2 +(2*1.5)

l3= l2+2
D2=2*d2

Design Of Rocker Arm Cross Sections

STEP-1
Bending stress

M=Moment in N.mm

b =M/Z

3
Z=Section modulus in mm

M=Fe*l
M=Fe*(l-d/2)
2

Z=1/6*t1* D1

L=Effective length of rocker arm in

mm

b =70 N/
mm2

t=thickness in mm

Design Of Push Rod

STEP1
Eulers Formula

WC r =

W= Load in N
2

*E*I/ l2 I in

M=Factor of Safety

WC r =W*M in N

D=Diameter of the push rod

I= Moment of Inertia of Push rod(
3

D=1.25d
(For tubular pushrod)

mm

L=l

)
2

E=Youngs Modulus in N/ mm

D
4

I=
- d )
64

D=0.8d to 1.25d

l= Length in mm
D= Outer Diameter
d= Inner Diameter
29

(For solid push rod)

I= 64

D4

30