The Effect of Novel Surface Textures on Tappet Shims on Valvetrain Friction and Wear

Abstract

In an engine, the valvetrain contributes about 6–10% of the total frictional loss depending on the architecture. The cam and the tappet contact in a direct acting mechanical bucket-type valvetrain offers opportunities for friction reduction. Work has been done in the past to reduce the frictional loss at the cam and tappet contact through use of lightweight materials to reduce the reciprocating mass, the improved surface finish, and the low friction thin film coatings. This investigation explored the potential for additional friction reduction through the use of novel surface textures on tappet shims. The surface textures were produced on tappet shims using two techniques: (a) regular patterns like parallel line V-grooves, and square grooves, circular V-grooves, and spiral V-grooves using a diamond tool, and (b) random irregular dimples using either ceramic peening or steel shot peening. The friction performance of these shims was compared with standard production shims and isotropic finish on production shims. Friction was measured using a motored valvetrain rig using a 3.0 L cylinder head. The friction response was different on each type of groove and dependent on the speed and the oil temperature. The shims with parallel line V-grooves showed the highest friction reduction (up to 35%) compared to the production shims. There appears to be no significant difference in wear pattern on cam lobes tested against production shims and shims with parallel line V-grooves. Also, the wear rate of a shim with parallel line V-grooves was no worse than the production shims. The random dimples created by peening did not offer any friction reduction, probably due to the increased surface roughness.

KEY WORDS:

• Surface Textures
• Valvetrain
• Friction
• Wear
• Radionuclide Technique
• Engine Oil
• Ceramic Peening
• Steel Shot Peening

ACKNOWLEDGEMENTS

The authors would like to acknowledge the assistance of Bob Cross, Dennis Roper, Greg Ciavattone, and Nick Wade in the Ford RIC Components Laboratory for the design, installation, troubleshooting, instrumentation, and setting up the data acquisition system, Sherry Lopez for generating the CAD drawing of parts, the machine shop personnel for the fabrication of parts, and Cory Phillips for acquiring wear data using the radionuclide measurement system.