KMEM 4344 TRIBOLOGY

Goh Cheng Fang Lim Cheng Siong Ng Kong Han Pang Ken Yew Sin Li Jiang Tan Chun Keat

KEM 090013 KEM 090022 KEM 090047 KEM 090048 KEM 090052 KEM 090056

Pushrod advantages disadvantage by Goh Cheng Fang

Pushrod failure by Pang Ken Yew

SOHC advantages & disadvantage by Sin Li Jiang

SOHC failure by Tan Chun Keat

DOHC advantages & disadvantage by Ng Kong Han

DOHC by Lim Cheng Siong

OVERHEAD VALVE (OHV) / PUSHROD / I-HEAD

ENGINE

ADVANTAGES
Smaller overall packaging: more compact than OHC engine of comparable displacement since camshaft located inside the engine block Less complex drive system: less complex camshaft drive system since its camshaft positioned just above crankshaft, thus can be run with a much smaller chain or even direct gear connection.

DISADVANTAGES
Limited engine speeds or RPM: more valve train moving parts, thus more valve train inertia and mass. If the pushrods are improperly designed, there is a tendency to flex or snap at high engine speeds. Limited cylinder head design flexibility: valves number and position, intake ports size and shape are limited by the pushrods and the need to accommodate them in the head casting. Noise and Refinement: noisier due to the increased complexity of the valve train and the adoption of chain or gear based camshaft drive. Maintenance: need to remove the engine whenever camshaft work is required

PUSHROD FAILURE

Large amounts of sludge and sticky lacquer deposit on the cylinder intake ports. Some of the ports are almost completely blocked, severely restricting the airflow.

1. Misalignment or fitting error in mounting and connecting the push rod to the rocker arm may have been the root cause of the damage. 2. This leads to insufficient air intake and removal of exhaust gases. 3. Under this condition the fuel combustion is not be complete resulting in formation of large amounts of soot and sludge as indicated in the oil analysis and inspection of the cylinder. 4. Furthermore the build up of sludge and varnish at the exhaust ports, which restricts gas flow, also resulted in a poor air/fuel ratio.

ADVANTAGES AND DISADVANTAGES OF SOHC

Advantages

Generally less expensive to manufacture and low maintenance cost Small in size Designs offer reduced complexity compared to overhead valve designs More power due to straighter intake runners(no pushrod ports to obstruct -shape/airflow) and higher rpm limit due to lighter valvetrain, easier to run multiple valves for more airflow

 Disadvantages

Physical size of the engine increases due to valve train on top of cylinder heads than being contained in the block when compared to a pushrod motor, need more speciality tools to work on/more training to work on Limits the valve angle, the basic inertia higher than the less high-performance switch operation High cost If the springs were not strong enough, the valves might come away from the rocker arms and snap back Reduce efficiency due to moving part

SINGLE OVERHEAD CAM (SOHC)

FAILURE DUE TO STRESS

Fatigue Pitting Abrasive Wears occurs on the lifter/follower

ROCKER ARM STRESS ANALYSIS

FAILURE OF THE TIMING BELT

ADVANTAGES AND DISADVANTAGES OF DOHC

 Advantages

Higher performance Can produce more power Run at higher speed Combustion of fuel more efficient
Disadvantages

More complex and more expensive design

More weight

FAILURE IN CWear LOBE AM

Wear and damage typically occurs at the nose of the lobe or slightly before the nose. Focusing on the wear only; notice how the entire length of the lobe is worn. Pitting Pitting is not normal for any lobe and is considered to be damage. Usually caused by corrosion pitting and metal fatigue. Very common with low usage engines.