Analytical and Experimental Study of Cam Follower Wear in a Diesel Engine

The valve train system plays a critical role in the performance and longevity of internal combustion engines. This paper presents a comprehensive investigation into the performance and durability of valve train systems in diesel engines, uncovering significant findings during durability validation. Extensive durability evaluations were conducted, including valve train overspeed test cycles and fatigue test cycles, to simulate real-world scenarios and assess component resilience. This study focuses on wear patterns observed in the cam and follower arrangements, highlighting their critical influence on engine performance and lifespan. The research investigates the root cause of wear by analysing wear patterns and evaluating the kinematic and dynamic behaviour of the valve train system through analytical calculations. The impact of combustion forces, pushrod rotation at the hydraulic rocker arm, and follower rotation are also explored in depth. Leveraging insights from these evaluations, a design upgrade was implemented using numerical simulation methods to address the observed wear. Improved samples were rigorously tested, and results were correlated with simulation outcomes to validate enhancements. This research offers practical insights into mitigating cam follower wear while underscoring preventive strategies and establishing a systematic framework for designing critical valve train components. The findings contribute to enhancing engine durability and ensuring optimal performance, making it a valuable resource for professionals in engine design and development.