Most of the IC engines used in the market have roller cam and follower mechanisms, having a line contact between the cam and the roller follower. In a effort to improve the mechanical efficiency of the mechanism the company requires us to change the line contact to a point contact. Hence it is required to change the flat roller follower to a curved profile. The existing cam & follower mechanisms used in Internal Combustion engines have a line contact between them causing frictional losses.

1. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp. 99-105© IAEME
99
EXPERIMENTAL ANALYSIS OF CAM ROLLER OF
INTERNAL COMBUSTION ENGINE BY CHANGE IN
AREA OF CONTACT
Prof. L. B. Raut. Guide& (M.E Co-ordinator) 1
, Akkamahadevi G. Chanagond (Kalyankar) 2
1,2
SVERI’S, college of Engineering, Pandharpur
ABSTRACT
Most of the IC engines used in the market have roller cam and follower mechanisms, having
a line contact between the cam and the roller follower. In a effort to improve the mechanical
efficiency of the mechanism the company requires us to change the line contact to a point contact.
Hence it is required to change the flat roller follower to a curved profile. The existing cam &
follower mechanisms used in Internal Combustion engines have a line contact between them causing
frictional losses. These frictional losses in present line contact are being considered on the higher
side. These frictional losses affect the total efficiency of an Internal Combustion engine. The
mechanical efficiency of cam & follower mechanism is to be increase by minimising the frictional
losses.The roller of rocker arm of a Hero Honda passion bike is replaced by new one to check
performance experimentally.
Keywords: Cam; Follower; Line contact; Point Contact; Vibration Analysis;
I. INTRODUCTION
In the 21th
century, with the advance technologies the various vehicles have been modified as
per the requirement of a consumer. Sometimes there is modified ignition system, modified shape,
different cylinder arrangements etc. Thus we have decided to change the shape of a roller. The roller
of the cam follower mechanism is of flat type; which makes line contact with cam. This line contact
of roller with cam will be changed to point contact by doing modification in the geometry of a roller.
The modified geometry of a roller should satisfy conditions:
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2. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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1. It should make point contact with cam of cam-follower mechanism.
2. The values of stresses of an original geometry and modified geometry should be within limit.
3. The value of frequencies of an original geometry and modified geometry should be within
range.
The dimensions required for roller is measured manually by using vernier caliper in the
workshop of a college as shown in figure 1 below. Another data required for analysis of a roller is
given by a company as shown in the table 1 below.
Fig: 1. Details of Rocker Arm, cam roller
Table: 1 Properties
1 Material 100cr6
2 Young's modulus 2.1e5MPas
3 Poisson Ratio 0.3
4 Density 7.850×10-6
Kg/mm3
5 Yield Strength 410MPa
II. TEST CRITERIA
1. Roller dimensions of Old Line & New Point contact roller
Width =8.1mm Width =8.1mm
Fig 2. Dimension of old and New Roller
Outer Dia.
18.24 mm
Inner Dia.
12.17 mm
Dia. 12.17
mm

3. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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Total 4 tests are conducted on motorcycle engine (Hero Honda passion) with replaced
Stainless tungsten chrome steel roller –(N8) which is case hardened & with old roller also.
Test 1: Measurement of vibration parameters with old line contact roller.
Test 2: Measurement of Noise with old line contact roller.
Test 3: Measurement of vibration parameters with new modified point contact roller.
Test 4: Measurement of noise with new modified point contact roller.
2. Experimental set up of vibration parameters with old line contact and new modified contact
roller
Fig 2: Measurement of vibration parameters with old line and new modified contact roller
Above shows close up of accelerometer attached magnetically to the engine that vibration
test is going on with the accelerometer sensor held in hand further stuck to engine body I C engine of
Hero Honda passion motor cycle. These readings are stored in FFT analyzer shown and later on
analysed in SWAN TECH software given by FFT supplier to produce graphs.
3. Experimental set up of noise with old line and new modified point contact roller
Fig 3: Measurement of noise with old line and new modified point contact roller

4. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp.
Above (Photo) shows that noise test is going on with the noise sensor probe held in hand at
the approximately same distance for all four sides of I C engine of hero Honda passion motorcycle to
get a average reading. These tests are taken for old and new roller t
These readings are stored in FFT analyser and later on analysed in mat lab to produce graphs
III. RESULT AND DISCUSSION
1. TIME DOMAIN ANALYSIS
Graph 1:
Above Graph shows Maximum amplitude is
to be reduced. Time span is taken 15 seconds for every reading.
2. TIME DOMAIN ANALYSIS
roller)
Graph 2:
Above Graph shows maximum amplitude is
reduced. Time span is taken 15 seconds for every reading. In old roller it was
our optimization is successful. The amplitude level decreases considerably by new roller.
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
6359(Online), Volume 6, Issue 2, February (2015), pp. 99-105© IAEME
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(Photo) shows that noise test is going on with the noise sensor probe held in hand at
the approximately same distance for all four sides of I C engine of hero Honda passion motorcycle to
get a average reading. These tests are taken for old and new roller that is line and point contact type.
These readings are stored in FFT analyser and later on analysed in mat lab to produce graphs
RESULT AND DISCUSSION
ANALYSIS OF VIBRATION SIGNAL (with old line contact roller)
Graph 1: Time domain Analysis of vibration signal
shows Maximum amplitude is 11mm shown in graph which is very high need
to be reduced. Time span is taken 15 seconds for every reading.
ANALYSIS OF VIBRATION SIGNAL (with new modified point contact
2: Time domain Analysis of vibration signal
shows maximum amplitude is 3mm shown in graph which is very low i.e.
reduced. Time span is taken 15 seconds for every reading. In old roller it was 11 mm
The amplitude level decreases considerably by new roller.
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
© IAEME
(Photo) shows that noise test is going on with the noise sensor probe held in hand at
the approximately same distance for all four sides of I C engine of hero Honda passion motorcycle to
hat is line and point contact type.
These readings are stored in FFT analyser and later on analysed in mat lab to produce graphs.
OF VIBRATION SIGNAL (with old line contact roller)
shown in graph which is very high need
with new modified point contact
shown in graph which is very low i.e.
11 mm so high. Hence
The amplitude level decreases considerably by new roller.

5. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
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3. TIME DOMAIN ANALYSIS OFACOUSTIC (NOISE) signal old
Graph 3: Time domain Analysis of acoustic (noise) signal
Above Graph shows Maximum amplitude is
need to be reduced. Time span is taken 15 seconds for every reading.
4. TIME DOMAIN ANALYSIS OFACOUSTIC (NOISE) signal New
Graph 4: Time domain Analysis of acoustic (noise) signal
Above Graph shows Maximum amplitude is
Time span is taken 15 seconds for every reading.
optimized roller. Hence our optimization is successful.
by new roller.
5. Vibration spectral analysis
Comparison of effect on amplitude & frequency by both rollers
Shows the vibration spectrum of old roller at idling speed of motorcycle (pink line) and
modified point contact roller (black line)
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
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S OFACOUSTIC (NOISE) signal old roller
Time domain Analysis of acoustic (noise) signal
shows Maximum amplitude is 50000 DB shown in graph which is very high
need to be reduced. Time span is taken 15 seconds for every reading.
S OFACOUSTIC (NOISE) signal New roller
Time domain Analysis of acoustic (noise) signal
Maximum amplitude is 45000 DB shown in graph which is reduced.
Time span is taken 15 seconds for every reading. The amplitude level decreases considerably by new
Hence our optimization is successful. The amplitude level decreases consider
Vibration spectral analysis
Comparison of effect on amplitude & frequency by both rollers with old line contact roller
Shows the vibration spectrum of old roller at idling speed of motorcycle (pink line) and
contact roller (black line)
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
© IAEME
roller
Time domain Analysis of acoustic (noise) signal
shown in graph which is very high
roller
Time domain Analysis of acoustic (noise) signal
shown in graph which is reduced.
The amplitude level decreases considerably by new
The amplitude level decreases considerably
with old line contact roller.
Shows the vibration spectrum of old roller at idling speed of motorcycle (pink line) and with new

6. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp. 99-105© IAEME
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Graph 5: Comparison of effect on amplitude & frequency by both rollers
6. RMS VALUE
IV. CONCLUSION
The change of roller can significantly reduce the costs of maintenance. In this research,
vibration and acoustic signals were used in an engine of motorcycle. It was shown that various types
of signals can be detected successfully by both types of rollers by acoustic and vibration signals
analysis. The acoustic analysis method has gained wide industrial acceptance for engine condition
monitoring. In this dissertation, shows the considerable freedom in positioning of the microphones -
distance and plane with respect to the source, and being able to detect the characteristic frequency
spectrum of the engine and consequently diagnosis using advanced signal processing. In this
dissertation work, experimentation is carried out to vibration & noise level difference through
acoustic and vibration analysis and feasibility of practical application of new modified roller in
engine of motorcycle is investigated. The acoustic and vibration spectrums obtained for different
rollers are presented on which following conclusions can be drawn.
1. Using Frequency Domain Spectrums
With new point contact roller & old line contact roller a comparison shown that it reflects the
change in spectrum. It is observed from the amplitude of frequency has decreased
considerably.
2. Using Time Domain Spectrums
With comparison of time domain spectrum, it is observed that an RMS value was decreased
by the use of new point contact roller in engine of motorcycle.
New roller Old roller
VIBRATION 0.9331 1.0233
ACOUSTIC 13404.7 14624.2

7. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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