1

CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION TO ROCKER ARM
The rocker arm is used to actuate the inlet and exhaust valves motion as
directed by the cam and follower. It may be made of cast iron, cast steel, or
malleable iron. In order to reduce inertia of the rocker arm, an I-section is used
for the high speed engines and it may be rectangular section for low speed
engines.
In four stroke engines, the rocker arms for the exhaust valve are the most
heavily loaded. Though the force required to operate the inlet valve is relatively
small, yet it is usual practice to make the rocker arm for the inlet valve of the
same dimensions as that for exhaust valve.

Fig.1.1 Rocker Arm
A typical rocker arm for operating the exhaust valve is shown in Fig.1.1
The lever ratio a / b is generally decided by considering the space available for
rocker arm. For moderate and low speed engines, a / b is equal to one. For high
speed engines, the ratio a / b is taken as 1/ 1.3.
2

The various forces acting on the rocker arm of exhaust valve are the gas
load, spring force and force due to valve acceleration.
1.2 APPLICATION OF ROCKER ARM
1.2.1 Valve Gear Mechanism
The valve gear mechanism of an I.C. engine consists of those parts which
actuate the inlet and exhaust valves at the required time with respect to the
position of piston and crankshaft. Fig. 1.2 (a) shows the valve gear arrangement
for vertical engines. The main components of the mechanism are valves, rocker
arm, valve springs, push rod, cam and camshaft.

Fig.1.2 Valve gear mechanism
The fuel is admitted to the engine by the inlet valve and the burnt gases
are escaped through the exhaust valve. In vertical engines, the cam moving on
the rotating camshaft pushes the cam follower and push rod upwards, thereby
transmitting the cam action to rocker arm. The camshaft is rotated by the
toothed belt from the crankshaft. The rocker arm is pivoted at its centre by a
fulcrum pin.
3

When one end of the rocker arm is pushed up by the push rod, the other
end moves downward. This pushes down the valve stem causing the valve to
move down, thereby opening the port.
When the cam follower moves over the circular portion of cam, the
pushing action of the rocker arm on the valve is released and the valve returns to
its seat and closes it by the action of the valve spring.
In some of the modern engines, the camshaft is located at cylinder head
level. In such cases, the push rod is eliminated and the roller type cam follower
is made part of the rocker arm. Such an arrangement for the horizontal engines
is shown in Fig.1.2 (b)













4

CHAPTER 2
LITERATURE SURVEY
N. Lenin Rakesh [1] has been done the project to find out the stress
analysis of rocker arm and the hand crank by using finite element analysis
software ANSYS. The structure of the hand crank and rocker arm model was
performed using pro-E 4.0 version. Then finite element analysis are performed
using ANSYS. The tensile stress of rocker arm and torsional stress of hand
crank is calculated manually and is being compared with the experimentally
obtained results.
Siraj Sheikh [2] has been Rocker arm of Tata Sumo victa that was
designed and analyzed to find the critical regions. CAD models of Rocker Arm
was created using Pro/E and ANSYS V11software was used for analysis of
rocker arm. The CAD model was inputted in ANSYS Workbench and
Equivalent Stress and Maximum Shear Stress was found. The obtained results
provided by ANSYS Workbench are compared to the results obtained by
manual calculation.
Syed Mujahid Husain [3] has been optimized in rocker arm design and
material for better performance. This project present what rocker arm is, where
it is used and why it is used, History related to rocker arm and it working is
described. Various types of rocker arm used in vehicles and different materials
used for making rocker arm are studied in this project. Reasons for Failure of
rocker arm are also discussed in this project.
Mohd Hafiz Bin Ghazalli [4] has been project used the cam, rocker
arms, valve lifter, exhaust valve and accessories used in 4G13 engine in type.
Solidworks, Cosmosmotion and Algor software are used for determination of
stress concentration on the components.
5

CHAPTER 3
ANALYTICAL DESIGN OF ROCKER ARM
3.1SPECIFICATIONS OF VALVE
We are going to design a rocker arm using analytical method of
calculation for that taking some standard specification are given on following
Table 3.1
Table 3.1 Specification of valve
Parameters Value
Diameter of the valve head 80 mm
Lift of the valve 25 mm
Mass of associated parts 0.4 kg
Angle of action of camshaft 110
Speed of the crankshaft 1500
Pressure on exhaust valves 0.4 N/mm
2

Suction pressure 0.02 N/mm
2

Angle between the two arms 135
3.2 DESIGN CALCULATION
First of all, the various forces acting on the rocker arm of the exhaust valve
shown in Fig. 3.2
Gas load on the valve,
P
1
= (/4) d
v
2
p
c

= (/4) 80
2
0.4
= 2011 N
6

Weight of associated parts with the valve,
w = m g
= 0.4 9.8
= 3.92 N

Fig. 3.1 Layout of Rocker Arm
Total load on the valve,
P = P
1
+ w
= 2011 + 3.92
= 2014.92 N
7

Initial spring force considering weight of the valve,
F
s
= (/4) d
v
2
p
s
w
= (/4) 80
2
0.2 3.92
= 96.6 N
The force due to valve acceleration (F
a
) may be obtained as follows
Speed of camshaft
= N/2
= 1500/2
= 750 rpm
Angle turned by the camshaft per second
= (750/60) 360
= 4500 deg/s
Time taken for the valve to open and close,
t = (Angle of action of cam/Angle turned by camshaft)
= 110/4500
= 0.024 s
Maximum acceleration of the valve
a =
2
r = (2/t)
2
r
= (2/0.021)
2
0.0125
= 857 m/s
2

8

Force due to valve acceleration, considering the weight of the valve,
F
a
= m a + w
= 0.4 857 + 3.92
= 346.72 N
Maximum load on the rocker arm for exhaust valve,
F
e
= P + F
s
+ F
a

= 2014.92 + 96.6 + 346.72
= 2458.24 2460 N
Since the length of the two arms of the rocker are equal, therefore, the load at
the two ends of the arm are equal, i.e. F
e
= F
c
= 2460 N.
We know that reaction at the fulcrum pin F,
R
F
=

= 4545 N
3.2.1 Design of fulcrum pin
Let d
1
= Diameter of the fulcrum pin, and
l
1
= Length of the fulcrum pin
= 1.25 d
1

Consider the bearing of fulcrum pin. Load on the fulcrum pin (R
F
),
4545 = d
1
l
1
p
b

9

= d
1
1.25 d1 5 (p
b
= 5 N/mm
2
)
= 6.25 (d1)2
(d
1
)
2
= 4545 / 6.25
= 727
d
1
= 26.97 30 mm
l
1
= 1.25 d1
= 1.25 30
= 37.5 mm
Check the average shear stress induced in the pin. Since the pin is in double
shear, therefore, load on the fulcrum pin (R
F
)
4545 = 2 (/4) d
1
2

= 2 (/4) 30
2

= 1414
= 4545/1414 = 3.2 N/mm
2

This induced shear stress is quite safe,
External diameter of the boss,
D
1
= 2d
1

= 2 30
= 60 mm

10

Assuming a phosphor bronze bush of 3 mm thick, the internal diameter of the
hole in the lever,
d
h
= d
1
+ 2 3
= 30 + 6
= 36 mm
Check the induced bending stress for the section of the boss at the fulcrum
which is shown in Fig. 3.2

Fig. 3.2 Sectional view of Boss at fulcrum
Bending moment at this section,
M = F
e
l
= 2460 180
= 443 10
3
N-mm
Section modulus,
Z = [(1/12) 37.5 (60
3
36
3
)] (60/2)
= 17640 mm
3

11

Induced bending stress,

b
= M/Z
= 443 10
3
/17640
= 25.1 N/mm
2
The induced bending stress is quite safe.
3.1.2 Design for fork end
Let d
2
= Diameter of the roller pin, and
l
2
= Length of the roller pin
= 1.25 d
2

Consider bearing of the roller pin. Load on the roller pin (F
c
),
2460 = d
2
l
2
p
b

= d
2
1.25 d
2
7 (p
b
= 7 N / mm
2
)
= 8.75 (d
2
)
2

(d
2
)
2
= 2460 / 8.75
= 281
d
2
= 16.76
18 mm
l
2
= 1.25 d
2

= 1.25 18
= 22.5 24 mm
12

Check the roller pin for induced shearing stress. Since the pin is in double shear,
therefore, load on the roller pin (F
c
),
2460 = 2 (/4) d
2
2

= 2 (/4) 18
2

= 509
= 2460/509
= 4.83 N/mm
2

This induced shear stress is quite safe.
The roller pin is fixed in the eye and thickness of each eye is taken as one-half
the length of the roller pin.
Thickness of each eye,
t
2
= l
2
/2
=24/2
= 12 mm
Check the induced bending stress in the roller pin. The pin is neither simply
supported in fork nor rigidly fixed at the end. Therefore, the common practice is
to assume the load distribution as shown in Fig. 3.3.
The maximum bending moment will occur at YY. Neglecting the effect of
clearance, we have
Maximum bending moment at Y Y,
M = (F
c
/2) [(l
c
/2) + (t
2
/3)] [(F
c
/2) (l
c
/4)]
= (2460/2) [(24/2) + (12/3)] [(2460/2) (24/4)]
13

= 12300 N-mm

Fig. 3.3 Sectional view of Roller End
Section modulus of the pin,
Z = (/32) d
2
3

= (/32) 18
3

= 573 mm
3

Bending stress induced in the pin
= M/Z
= 12300/573
= 21.5 N/mm
2

This bending stress induced in the pin is within permissible limits.
14

Since the radial thickness of eye (t3) is taken as d2 / 2, therefore, overall
diameter of the eye,
D
2
= 2d
2

= 2 18
= 36 mm
The outer diameter of the roller is taken slightly larger (atleast 3 mm more) than
the outer diameter of the eye.
In the present case, 42 mm outer diameter of the roller will be sufficient.
Providing a clearance of 1.5 mm between the roller and the fork on either side
of the roller, we have
l
3
= l
2
+ 2 (t
2
/2) + 2 1.5
= 24 + 2 (12/2) + 3
= 39 mm
3.1.3 Design for tappet screw
The adjustable tappet screw carries a compressive load of F
e
= 2460 N.
Assuming the screw is made of mild steel for which the compressive stress (
c
)
may be taken as 50 MPa.
Let d
2
= Core diameter of the taper screw
The load on the tappet screw (F
e
)
2460 = (/4) d
c
2

c

= (/4) d
c
2
50
= 39.3 d
c
2

15

d
c
2
= 2460 / 39.3
= 62.6 or
d
c
= 7.9
8 mm
Outer or nominal diameter of the screw,
d = d
c
/0.84
= 8/0.84
= 9.52 10 mm
We shall use 10 mm stud and it is provided with a lock nut. The diameter of the
circular end of the arm (D
3
) and its depth (t
4
) is taken as twice the diameter of
stud.
D
3
= 2 10 = 20 mm
t
4
= 2 10 = 20 mm








16

CHAPTER 4
FEM ANALYSIS OF ROCKER ARM
The data from the analytical calculation is used for modeling the rocker
arm, the CAD modeling is done on CREO Parametric 2.0 as shown in Fig. 4.1

Fig. 4.1 Rocker Arm modeled using Creo parametric
Then the model is imported to FEM Software, the FEM package used for
is ANSYS 14.0
4.1 ANALYSIS OF ROCKER ARM
There are four analysis are carried out in a Rocker arm
1. Total deformation
2. Equivalent strain
3. Equivalent stress
4. Shear stress
17

4.2 MATERIAL PROPERTIES
The material used for selected rocker arm is structural steel and the
properties of the material are presented in the Table 4.1
Table 4.1 Material Properties of Structural steel
Parameters Value
Density 7850 kg m
-3

Youngs modulus 2E+5 MPa
Poissons Ratio 0.3
Bulk Modulus 1.6667E+5 MPa
Shear Modulus 7.6923E+4 MPa
Tensile yield strength 2.5E+02 MPa
Compressive yield strength 2.5E+02 MPa
Tensile ultimate strength 4.6E+02 MPa
4.3 DIMENSION OF ROCKER ARM
The Dimensions are obtained from the Analytical calculations done in
Chapter 3 and arranged in Table 4.2
Table 4.2 Dimensions of Rocker Arm
Parameters Value
Diameter of the fulcrum pin 30 mm
Length of the fulcrum pin 37.5 mm
External diameter of the boss 60 mm
Diameter of the roller pin 18 mm
18

Length of the roller pin 24 mm
Thickness of each eye 12 mm
Overall diameter of the eye 36 mm
Core diameter of the tappet screw 8 mm
Diameter of circular end of arm 20 mm
Depth circular end of arm 20 mm
4.4 MESHING
The mesh is done by default mesh element of ANSYS 14.0 using fine
mesh settings. The meshing must be very fine for obtain the highly accurate
analysis answer as shown in Fig. 4.2.

Fig. 4.2 Meshed model
4.5 LOADS AND BOUNDARY CONDITIONS
As shown in the Fig. 4.3 the loads and boundary conditions are assigned,
the analysis are carried out in without gravity settings.
19


Fig. 4.3 Boundary condition applied model
4.6 RESULTS
Following four results are produced using ANSYS
1. Total deformation
2. Equivalent strain
3. Equivalent stress
4. Shear stress
4.6.1 TOTAL DEFORMATION
The total deformation is obtained as shown in Fig. 4.4

Fig. 4.4 Total deformation
20

4.6.2 EQUIVALENT STRAIN
The Equivalent Strain is obtained as shown in Fig. 4.5

Fig. 4.5 Equivalent strain
4.6.3 EQUIVALENT STRESS
The Equivalent Stress is obtained as shown in Fig. 4.6

Fig. 4.6 Equivalent stress
21

4.6.4 SHEAR STRESS
The Shear Stress is obtained as shown in Fig. 4.7

Fig. 4.7 Shear stress











22

CHAPTER 5
CONCLUSION
The analytical design calculation has been calculated and then 3D
modeling of the Rocker arm is done by using Creo parametric 2.0 software. The
modeling was done using Creo by the help of the calculated parameters and the
values. The stress analysis of the Rocker arm was found out manually by using
formula and data taken from the Design data book, and then the specified stress
concentration was analyzed by using ANSYS. The result found was compared
with the values found out manually. The compared result was found
satisfactory.
From this project, it was found that the analytical calculations of new
section are more effective than that of older section.











23

REFERENCES
1. N. Lenin Rakesh, A. Thirugnanam and Jitesh Mishra Stress Analysis of
Hand Crank and Rocker ARM Middle-East Journal of Scientific Research
12 (12): 1687-1689, 2012, ISSN 1990-9233
2. Syed Mujahid Husain, Prof.Siraj Sheikh Rocker Arm: - A Review
International Journal of Innovative Research in Science, Engineering and
Technology Vol. 2, Issue 4, April 2013, ISSN: 2319-8753
3. Syed Mujahid Husain, Siraj Sheikh Design and Analysis of Rocker Arm
International Journal of Mechanical Engineering and Robotics Research.
Vol. 2, No. 3, July 2013, ISSN 2278 0149.
4. Mohd Hafiz Bin Ghazalli Finite Element Analysis Of Cam And Its
Follower Contact Stress Mechanism.
5. Khurmi R S and Gupta J K (2011), I.C Engine Parts, Machine Design, pp.
584-589 and 1192-1195.
6. Dong-Woo Lee, Soo-Jin Lee, Seok-Swoo Cho and Won-Sik Joo (2005),
Failure of Rocker Arm Shaft for 4-Cylinder SOHC Engine, Engineering
Failure Analysis,Vol. 12, No. 3, pp. 405-412.