Camshafts

Camshaft operation involves repeated surface stress under high Hertzian loads, particularly at the lobe–tappet interface. Each camshaft is manufactured from material grades selected based on load cycles, lubrication regimes, and operating temperatures — including chilled cast iron with controlled graphite morphology or induction-hardened EN40B steel with a hardened case depth exceeding 2 mm. Material certification, grain flow orientation, and post-heat-treatment microstructure validation ensure resistance to spalling, scuffing, and thermal fatigue. 

Torsional oscillations in camshafts can lead to valve phasing errors and timing irregularities, particularly in long or hollow cam configurations. Finite Element Analysis (FEA) is used during the design phase to model shaft deflection under peak torque and resonance frequencies. Countermeasures such as tuned mass dampers, optimized shaft diameters, and segmental hollow constructions are incorporated to mitigate harmonic amplification. Dynamic balancing is carried out using multi-plane balancing rigs to suppress critical speed issues.