FINAL YEAR PROJECT (PPKP FYP) Ept 445. 2015, s.

Development of Camshaft Machining Processes using Turning and

Milling CNC Machines

Siti Nurul Adura Daud1, Jamali Md Sah2

Abstract –Nowadays, camshaft is produced using CNC Cam Grinding machine in order to meet
the specification especially for the cam lobe. However, the cost of manufacturing the product
using the grinding machine alone is considered quite high according to one of the main
motorcycle manufacturer in the country. Therefore, a proposal has been discussed to consider
alternative processes that can be ventured to produce similar product as mentioned. This project
studies the option of utilising the CNC machines available at the labs to manufacture the
camshaft, which begins from regenerating the CAD data of the camshaft provided using a 3D
Scanner unit. The scanned data is used to construct the part drawing using CATIA and machining
simulation by CAM is used to generate the NC programming codes based on the turning and
milling processes that have been selected. Several types of cutting tools are chosen for the rough
cutting and finishing processes and these data are recorded for the cutting simulation. The
camshaft will be supported using a custom-made fixture during the process and the machined part
will be analysed according to the specifications and 3D images comparison will done using the
scanner to get the actual percentage error.

Keywords: Camshaft machining, Turning and Milling CNC Machines, CNC Cam Grinding
Machines, Reverse Engineering, Camshaft Lobes

camshaft is cast from iron molds and then undergo

numerous finishing processes until the cam lobes and
Nomenclature the shafts were in precise orientation [4]. The camshaft
CAD Computer Aided Design also can be manufactured as separate components then
the lobes, journals and gear were secure to the shaft
CAM Computer Aided Manufacturing either by an interference fit, by deforming the shaft or
CBN Cubic Boron Nitride by welded. This method has disadvantages that is when
welded, the welding heat adversely affected the temper
CMM Coordinate Measuring Machine
of the attached parts thus, another process which is
CNC Computer Numerical Control hardening is required. Another process that is used to
HSS High Speed Steel produce the camshaft is the forging process. Once the
forging is produced, the adjustments only can be made
NURBS Non rational uniform B-spline in the rotational location and profiles of the cam lobes.
Those adjustments are made in final machining and
grinding processes. However, the forging process is
expensive and the forging dies need to be modify for a
different cam lobe position and profile [5].
In 1953, the method of producing camshafts changes
I. Introduction to grinding process but in several ways which is
complicated and a long process [6]. Then, in 1983
A camshaft consists of a shaft and cam lobes [1]. It people strated to grind camshaft using CNC as in Fig
is a key part of the automobile engines and other 1.
internal combustion engines. Its quality and process
efficiency has a direct influence on the quality of
automobiles and the development of the entire
automobile industry[2]. In early history, the camshaft
is produce by grinding process by mechanically
copying the camshaft profiles from a master campack
but it has the disadvatages that is the generation of
accurate master campack for each new profile to be
produced is expensive [3]. Other than that, the
 Siti Nurul Adura Daud, Jamali Md Sah

Fig. 1. The CNC Cam Grinding machine system.

The direct grinding of camshafts using CNC

machine eliminates limitations produce by grinding
camshaft profiles uses the method of the master Fig.2. Reverse engineering process flowchart.
campack with time saving. CNC is a system that can
carry out data processing on the camshaft profile at a Based on the flowchart, the subject part of the
very high rate during the grinding process and can interest is the camshaft, while 3D Scanning is the method
control the machine axes to generate the correct profile of getting the shape or can be called as point of the
at high speeds with zero following error. The system surface. A point cloud is a set of 3D points or data
also use advanced CNC techniques to eliminate the coordinates that appears as a cloud or cluster. Usually the
physical master cam and copying hardware. The point clouds are not directly usable in most engineering
required form is generated by the CNC system from applications until they are converted to a proper format,
ideal cam form data generated by a CAD system. The such as a polygon mesh, nonuniform rational B-spline
advantages of this process is it removes the need to (NURBS) surface modes, or computer aided design
manufacture an accurate master cam, eliminate errors (CAD) models, as input for design, modelling, and
create by master cam and automatic compensation of measuring through a process referred as reverse
component size [3]. engineering [7]. The modification of the reverse
Now, almost all industries used the CNC concepts as engineering flowchart resulted in new flowchart of
the transformation of the conventational menthod. It is producing the new camshaft as shown in Fig.3.
a trend that the traditional grinding methods on all the
methods of producing camshaft previously are being
replaced by CNC Cam Grinding Machine because of
its high accuracy, effiecientcy and flexibility.
However, the CNC Cam Grinding Machine has some
difficult that is the need of experience, skilled worker
to ensure the accuracy of the camshaft by optimizing
the process parameters [2].
Basically, the limitation of School of Manufacturing
Engineering which did not has the CNC Cam Grinding
Machines has lead the new camshaft to be produce by
Turning and Milling CNC Machines. The method use
is same as other reverse engineering process which the
product need to be identify the all the dimension need
Fig.3. Methodology of producing the new camshaft.
to be measure first.

II.1. Methodology details

II. Experimental Details In producing the new camshaft, the existing product
need to be identify. The existing product is Honda Beat
This project is a reverse engineering project so the Stock camshaft (Fig.4.) that is previously produced by
reverse engineering methodology must be followed with CNC Cam Grinding Machine.
and an adjustment made to its method to get the precise
camshaft. The reverse engineering methodology is
illustrated in Fig. 2.

Fig.4.Honda Beat Stock camshaft

The dimension of the camshaft is taken using Vernier

Caliper for each parts diameter. Then, the surface
 Siti Nurul Adura Daud, Jamali Md Sah

roughness of the product is taken using the Surface 4

The
The milling operation
Roughness Tester. The camshaft then undergo the most for second lobe (the
key
work piece has turn
important process that is its being scan by using 3D 360o).
Scanner by FaroArm and the point cloud from the
Geomagic Software is later convert to the 3D Solid
2nd lobe
Model. The scanning process is important because its
interpret all the dimension of the camshaft especially the
lobe profile that is difficult to measure by using other
tool. After that, the machining process is decided. A 1st lobe
standard operating procedure for new camshaft
production is shown in TABLE I. Later, NC code is
generate for turning (roughing and finishing) parts and 5 The turning operation
milling (the lobe and key) parts. For turning, the NC code (finishing).
is generated manually using canned cycle but for milling
the NC code is generate automatically using CAM from
CATIA. Noted that the first and the second lobe has the
same shape but different direction so it use the same NC
code.

TABLE I
STANDARD OPERATING PROCEDURE FOR NEW CAMSHAFT
No. Picture Explanation
1 The first turning
operation (rough
turning). After the NC code is generated, the material, tool and
parameter is selected. The material use is medium carbon
steel JIS S45C that have some properties of EN8 steel. It
has the hardness of 160-200 HB.For turning, the tool use
is the HSS tool for turning, parting tool, the diamond
insert for roughing and finishing and the perting insert.
For milling, the tool use is the HSS tool 10mm 4-flute
(for the lobe) and HSS tool 6mm 4-flute (for the key).
The parameter use for turning and milling are show in
2 The first milling Table II and III.
operation for the first
lobe. TABLE II
THE PARAMETER FOR TURNING OPERATION
Process Spindle Spindle Feed rate, Feed rate
speed, speed, rough cut (mm/min)
rough cut finish cut (mm/rev)
Round lobe profile (rpm) (rpm)

Turning 1000 1000 0.20 0.05

(Roughing)
3 The milling operation Turning 1000 3500 0.25 0.1
The for the key part.
key (Finishing)

TABLE III
1st lobe
THE PARAMETER FOR MILLING OPERATION
Process Spindle speed Feed rate (mm/min)
(rpm)
Milling (Lobe 3500 400
Profile)
Milling (Key) 1000 300

Lastly, the product and prototype is fabricated. Then, the

analysis is made based on the feasibility of the turning
 Siti Nurul Adura Daud, Jamali Md Sah

and milling CNC machines to produce the new camshaft.
The analysis is also include the comparison of surface
roughness value and dimension.
III. Result and Discussion
The result is discussed based on three elements that
are, the surface roughness and the dimension. Other than
that, the limitation of Turning and Milling CNC
Machines in producing the new camshaft are also
analyzed.
III.1 Surface Roughness Tester Result
Fig.5 and Fig.6 show the points of surface test by
using Surface Roughness Tester for existing camshaft and
new camshaft. The surface roughness result obtained
from the Surface Roughness Tester is shows in Table IV
The requirements of the lobes surface finish is 0.40µm
thus the new camshaft lobes surface roughness is out of
specifications. Actually, the existing camshaft has fulfill
the requirement lobes surface roughness but because of
the rusting, the value is a bit higher. The higher value of
Ra in new camshaft cause by unconsistent parameter use
and there is no specific parameter find to get the Ra value
as same as the existing camshaft.
III.2 Dimensional Result
Fig.7 and Fig.8 show the dimensional part for the
existing and new camshaft that are taken by using CMM
and Vernier caliper. In specified, the diameter is taken by
using Vernier caliper and the length of the parts is taken
by using CMM. The dimensional result obtained is shows
in Table V.

Fig.7.Parts on existing camshaft

Fig.5.Points on existing camshaft surface

Fig.8.Parts on new camshaft

TABLE V
Fig.6.Points on new camshaft surface
DIMENSIONAL RESULT
TABLE IV Point Existing Camshaft Dimension New Camshaft Dimension
SURFACE ROUGHNESS TESTER RESULT (mm) (mm)
Point Existing Camshaft Surface New camshaft Surface
Length Diameter Length Diameter
Roughness, Ra (µm) Roughness, Ra (µm)
1 6.19 12.00 5.60 11.98
1 1.056 1.975
2 12.05 17.00 14.40 14.06
2 0.541 1.765
3 5.50 - 5.65 -
3 0.488 1.439
4 5.50 20.00 5.14 21.60
4 0.426 1.157
5 7.40 - 7.80 -
5 8.414 2.372
6 6.45 24.00 6.15 24.13
6 0.907 1.747
7 7.75 20.00 8.20 19.92
7 0.405 1.695
8 18.05 12.00 18.55 11.91

Based on Table IV, it is clearly shows that the new

The dimension in Table V shows that most of the new
camshaft surface roughness is higher that the existing
camshaft length is different from the existing camshaft
camshaft surface roughness except for point 5. At point 5,
length. The length of part 1, 2, 7 and 8 is difficult to
the surface of the existing camshaft is higher than the new
measure because of the groove part in between them. The
camshaft because it is produce by casting method before
groove parts cannot be measure by using the CMM
the grinding process is taken. The most important
because the probe is too large. The groove parts then is
roughness is the lobes surface roughness (points 3 and 4).
 Siti Nurul Adura Daud, Jamali Md Sah
measured by using Vernier caliper but the dimension
obtained by using Vernier Caliper is not accurate. The
right tool for the measurement of the groove is by using
Measuring Microscope. For the camshaft lobe (parts 3
and 5), the existing camshaft has inconsistent
measurement of the camshaft lobes thickness. So, in
producing the new camshaft, the maximum thickness of
camshaft lobes has been followed. For camshaft lobes
(parts 3), the maximum lobes thickness of the existing
camshaft is 5.50mm. Similarly, for the camshaft lobes
(parts 5), the maximum thickness lobes thickness of the
existing camshaft is 7.40mm. The error of the length
dimension of all parts of the camshaft is also caused by
the inappropriate technique of converting the Point Cloud
from the Geomagic Software to Solid Body in CATIA.
The lack of training and professional user also one of the
cause of the measurement error because the proper and
the best technique does not applied in taking the
measurement. Besides, the CMM by the Faro Arm need a
proper jig to hold the camshaft while measurement is
taken. The diameter of each of the parts is measured by
using Vernier caliper. The result obtained for the new
camshaft diameter is almost accurate to the existing
camshaft diameter. The diameter of the parts 3 and 5
which are the camshaft lobes is difficult to measure
because of the egg shape profile. The reason of the
diameter of the new and existing camshaft is almost
accurate is because the diameter of the existing camshaft
is not only measured from the drawing in the CATIA but
also were measured again by using Vernier caliper. For
part 2 diameter, the new camshaft has higher diameter
than the existing camshaft due to human error which is
that part is not measured by Vernier Caliper and the
measurement is taking directly from CATIA.
III.3 Limitation and Problem of CNC Turning
Machine
There are several problem face when using CNC
Turning machine to produce the camshaft. Firstly, the
partil tool has the limitation that it can cut the the small
groove that has the size less than 3mm. It is because the
width of parting tool itself is 3mm. Another limitation of
parting tool detected when it is used for turning
(roughing), to cut the workpiece with high hardness,the
parting tool or its insert will broke. Other than that the
CNC Turning Machine that are used, can not read the
canned cycle code G72 (axial cut). It only can read the
canned cycle code G71 (horizontal cut) which make the
cutting process is difficult especially for the groove part.
III.4 Limitation and Problem of CNC Milling
Machine
Actually, the existing camshaft has the keyway part as
shown in Fig.9. but because there is no fixture available
to hold the workpiece horizontally when the milling
operation is run. The key way part is also resist by the
lobe profiles when it is put horizontally in at the CNC
Milling Machine. So, the key way part is not made due to
the limitation of the fixture.
The key
way
Fig.9. The key way part in existing camshaft
IV. Conlusion
As a conclusion, the new camshaft is successfully
produced but not 100 % same as the existing camshaft
due to the limitation of measurement, limitation of
Turning and Milling CNC Machines and unsuitable
parameter used. The limitation and error cause the result
obtained for the existing and new camshaft to be
difference. This can be seen at Surface Roughness Tester
Result and Dimensional Result.
For future work, a experiment must be carried out to
find the optimize parameter that for carbon steel JIS with
the surface roughness desired. Other than that, for
finishing process for turning the CBN insert or carbide
insert shoud be use to get the good surface finish. For
milling, when mill the lobe profiles the carbide tool also
should be use with high spindle speed. Lastly, a further
investigation should be made by producing the camshaft
using 5-axis turning and milling CNC Machines and by
using 3-axis CNC turning machines.
Acknowledgements
The author would like to thank the School of
Manufacturing Engineering and MPU 17 CNC
Laboratory members for their helps in this experiment.
References
1. Harold, R. and H.B. Thomas, CAM MECHANISMS, in
Mechanical Design Handbook, Measurement, Analysis,
and Control of Dynamic Systems. 2006, McGraw Hill
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2. Deng, Z.H., et al., A hybrid model using genetic algorithm
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NC camshaft grinding. The International Journal of
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859-866.
3. Portas, G.N., D.R. Perkins, and J.R. Crookall, A High
Performance CNC Machine for Grinding Camshaft
Profiles. CIRP Annals - Manufacturing Technology, 1983.
32(1): p. 331-333.
4. Hughes, R.W., R.H. Brisson, and G.R. Brisson, Method of
making a cam shaft, 1988, Google Patents.
5. McAllister, D.K. and R.E. Hite, Method for manufacturing
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6. Price, R.E., Cam grinder, 1953, Google Patents.
 Siti Nurul Adura Daud, Jamali Md Sah

7. Wang, W., Reverse Engineering: Technology of

Reinvention. 2010: Taylor & Francis.

Authors’ information
1Siti Nurul Adura binti Daud
2Jamali Md Sah

Siti Nurul Adura Daud was born in Tangkak,

19 September 1992. She is currently working
towards the B.Eng in Manufacturing
Engineering from Universiti Malaysia Perlis,
expected to graduate on September 2015.

Jamali Md Sah was received his M.Sc in

Industrial Control Systems and B. Eng in
Mechanical Engineering from Salford
University, United Kingdom.