A Finite Element Method for Camshaft Cap Durability Analysis

In this study, a finite element analysis method is developed for simulating a camshaft cap punching bench test. Stiffness results of simulated camshaft cap component are correlated with test data and used to validate the model accuracy in terms of material and boundary conditions. Next, the method is used for verification of cap design and durability performance improvement. In order to improve the computational efficiency of the finite element analysis, the punch is replaced by equivalent trigonometric distributed loads. The sensitivity of the finite element predicted strains for different trigonometric pressure distribution functions is also investigated and compared to strain gage measured values. A number of equivalent stress criteria are also used for fatigue safety factor calculations. The severity of the loading experienced by the camshaft caps depends on whether the under study cap is on intake or exhaust camshaft side as well as the location of the associated cylinder on the engine. Design suggestions are given to meet cap durability requirements, based on engine bank and camshaft cap numbers.