WEL COME!!!

DESIGN OF VALVE
LAPPING
MACHINE FOR IC
ENGINE
Chapter one

Introduction to
Valve lapping
machine
• Valve lapping is process of creating a good
seat between engine valves and the
corresponding valve seat area.

• Valve lapping tools are not very effective, they

must replaced by the valve lapping machine.
 Objectives of the project

To design a machine which is:-

• Effective and efficient than previously used
• Reduce the labor cost
• Accurate to reduce wear and fatigue on
cylinder head and valve
• Durable
 Background of valve lapping
• modern lapping technology is evolved starting
from the Stone Age.
• few years ago peoples were used to lap an IC
engine by their hand.
• But latter it is modified by using lapping tool .
 Problem of the statement
manual valve lapping:-

• takes long time

• is labor intensive
• has low accuracy
• requires a specific technician
So we decided to design the valve lapping
machine.
 Significance of the project

• It is flexible to lap different type of engine

• Easy to use, operate and repair
• Reduced inspection requirements
• Optimum geometry and surface finish
• Better utilization of machine time
 
 CHAPTER TWO

LITERATURE REVIEW
• The internal combustion engine operates by
achieving a certain compression ratio
• if the air-fuel mixture leaks through the
seating, the volume of the air-fuel mixture will
change and combustion process will not be
accurate.
• Therefore it is vital to have a fully sealed
combustion chamber.
• the valve seating is very important in acquiring
a fully sealed combustion chamber. This is
done by lapping machine.
Valve lapping machine
Timing belt (open flat belt)

Small amount of installation work

Small amount of maintenance
High reliability
High peripheral velocities
Good adaptability to individual application
Shock and sound absorbing
 Hydraulic bottle jack

 Hydraulic bottle jack is used to adjust the lapping

machine vertically.

 This is extensively used for carrying and lifting the

weights of motor, belt and pulley, cam and cam shaft
and the upper frame(housing) during vertical
adjustment of the machine.
• This jack has three main advantages listed
below:-
1) Vertical adjustment of the machine as it laps
different sizes cylinder head.
2) Absorb shock and vibration when the
machine operates the task.
3) Carrying weights.
 Screw system
 The power screws (also known as translation
screws) are used to convert rotary motion into
translational motion.
 By this screw we can lap a numbers of valves
successively by adjusting horizontally with this
screw.
 This screw also uses for balancing mechanism
of the machine.
CHAPTER THREE
CONCEPT GENERATION
AND
DESIGN METHODOLOGY
 Concept generation
Design Alternative One
Requirements
 Ac motor
 Rack and pinion
 Cam, cam shaft and follower
 Adjusting screw
 Belt pulleys
 Base of the machine
 Table
 Working principle

• Cylinder head is laid above the base of the

machine and the electric Ac motor drives the
cam shaft by means of belt and pulley
mechanism.
• When cam and cam shaft rotates, follower
reciprocates up and downward to lap the cylinder
head. The vertical adjustment of the valve
lapping machine is done by rack and pinion.
• The horizontal adjustment is also done by power
screw which is rotated manually.
 Design Alternative two
Requirements
 Ac motor
 Hydraulic bottle jack
 Cam, cam shaft and follower
 Adjusting screw
 Belt and pulleys
 Base or bade of the machine
 Height indicator
 Table
 Plastic hammer
 Working principle.

 As the alternative one this machine is also

adjusted vertically, but the adjusting mechanism is
hydraulic bottle jack instead of rack and pinion.
The horizontal adjustment is also the same with the
alternative one.
 Main advantages of alternative two over alternative
one:-
 Valve lapping machine needs high accuracy, hydraulic
system is most accurate from other lifting systems.
 Noiseless system
 Absorbs vibration of the machine
 CHAPTER FOUR

RESULT AND DESCUSION

 pulley and Flat Belt
Motor specifications
Design analysis of pulley and belt
Material selection
Belt materials:-nylon, glass fiber and rubber
back/teeth
Pulley material:-aluminum alloy steel
 cam shaft and cam

Manufacturing process of cam

 The dies are prepared by spraying the mold cavity
with lubricant.
 The dies are then closed and molten metal is injected
into the dies under high pressure.
 Material selection

Cam-material mild steel

 properties
 Availability and low cost
 High compressive and fatigue resistant
 Heat resistance
 Abrasive and wear resistance
 
 Design of spring

Design analysis
Material selection of spring
 Carbon steel
• Suitable for helical compression spring
• Higher quality
• High strength
• Heat resistant (range from 780-8500c)
Manufacturing process
• Spring is manufacturing by lathing
Cost analysis
 Cost of items(ETB)
No. Item quantity cost/quantity(ETB)

1 Lever 1 62.16 62.16

2 Plunger 1 62.82 62.82

3 Plunger cylinder 1 76.35 76.35

4 Ram cylinder 1 84.97 84.97

5 Reservoir 1 83.5 83.5

6 Base cylinder 1 810 810

7 Base machine 1 8250 8250

8 Power screw 1 241.45 241.45

9 Pulley 2 100+200 300

10 Belt 1 130 130

11 Cam shaft 1 2500 2500

12 Bearing 2 288 576

13 Spring 5 35 175

14 Screw 4 20 80

15 Motor 1 3000 3000

Total cost 16356.35

 CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
Conclusion
we can conclude as the following:-
• Valve lapping mechanism was implemented replacing
manual labor.
• Cylinder head can be lapped without sliding on the base
• Vertical height adjustment problem was solved by
introducing hydraulic bottle jack
• Valve lapping mechanism was designed as an assembly of
several parts easing any maintenance to the machine.
 Continued…….
• Structural integrity of machine bed, cylinder
head supports, tension spring and cam against
loads and torques were fine and the designs
are successful.
• Weight of the whole machine is less
• All the designs could be completed
successfully
 Recommendation
• As it is known, IC engine is the heart of a
vehicle
• This shows any fail on the engine means fail
on the vehicle.
• . Then engine needs accurate repair and care.
• So we strongly recommend companies and
garages to stop wasting their time through
using the previous lapping methods.
 Continued…
• Our recommendation is also for researchers
who work on this type of machines and use
our paper as a source, try to change the
hydraulic system into computerized system
• Generally this valve lapping machine has great
advantage to all garages and workshops
THANK YOU!!!