HEMISFEAR
11-25-08, 09:20.49 AM
When looking for articles about camshaft ramp rates and false knock, I came across this and thought I'd share...with a reference if you want to look into it further....
Cam Truth by Buddy Rawls, 10/2005
Introduction
More articles have probably been written about camshafts than any other engine component. To me, the camshaft, or more specifically the valve timing events are the most important aspect of an engine's ability to perform. This write-up is not going to describe how an engine works, by using text book explanations for the cycles in the 4-stroke naturally aspirated engine. It is intended to present the relationship of the camshaft to the engine combination and apply that relationship to engine performance characteristics. I will incorporate various lines of reasoning used by the media and enthusiasts, and how they apply to engine modifications. The intent is not to prove right or wrong, but to help provide a clearer understanding. I present this write-up based on my experience of modeling engine parameters to calculate power capability and flow requirements. As always, there are assumptions to simplify the subject. None of the thermodynamic properties, pressure wave phenomena, or combustion aspects will be covered in this write-up. In order to address the various ideas, an engine model will need to be visualized. The engine models are simple, however, I consider them to be a realistic approximation of the engine as a system, focusing on flow and valve timing requirements.
The Understandable Engine
Engine Modifications and Cylinder Pressure
First, let's look at what an engine does. The first inclination is to say that an engine produces power, typically noted as horsepower. This is not really the case. An engine produces torque (which is measured in terms of work on a dyno) and when applied over a unit of time (as in revs per minute), you get power. The formula that relates horsepower to torque is this: HP = Torque x RPM / 5252. The 5252 is not some sort of experimentally derived constant. It is simply a units conversion.
Let me explain in very simple terms: an engine moves or exchanges air; it is basically a pump. It's output directly relates to how much pressure is produced from the trapped charge in the cylinder as the piston travels up and down its bore . There are many things that go into this: crankshaft geometry, cylinder volume, RPM, inlet and exhaust port characteristics, and sealing capability just to name a few of the more important ones (to me). You can alter the breathing aspects and cylinder volumes and crankshaft geometry, but it all comes down to making cylinder pressure. The sole component of the engine that really controls cylinder pressure is the camshaft and its associated control of the valve events, regardless of inlet/exhaust capabilities and bottom end geometry.
Valve timing is made up of timing events measured lift per degree of crank rotation. Most conversations and articles always seem to focus on the valve duration and maximum valve lift. The thing that must be remembered, is that those lifts, durations, and lobe separation angles come from the timing events, and not the other way around. So when subjects tend to move toward specific durations and lobe separation angles, be aware, that unless you are talking about identical engines (geometry, cylinder volume, inlet and exhaust characteristics, etc.), the specific numbers and comparisons do not mean much. The subject needs to focus on cylinder pressure and not on whether a cam is classified as a racing or a street grind.
Almost every performance enthusiast understands that increased flow and/or increased cylinder volume gives increased power. However, not all increases in flow capability or engine size yield positive results. Sometimes a performance decrease occurs. The statement really needs to be reworded to this: increased flow and/or cubic inches gives increased power capability. There is a big difference. The revised statement demonstrates that performance gains are dependent on the set-up in some way.
Simple Cylinder Pressure Model
For the next portion, consider simple cylinder pressure models. Take a look at what happens as the crankshaft rotates and moves the piston up and down the cylinder bore. Imagine if you could cap off the top of the cylinder bore and install a pressure guage. What happens if you rotate the crank, moving the piston upward, decreasing the overall cylinder volume? Then what happens when the piston moves down, increasing the volume? As the volume changes, the pressure within the enclosed cylinder is increased or decreased. A decrease in volume will generate an increased pressure and a volume increase will generate a decrease in pressure (vacuum).
Now, incorporate a port on top of the cylinder bore. Inside the port, imagine a small piston with a spring that can extend or compress as it is pushed or pulled in the port. Now rotate the crankshaft. The piston moves up and down the cylinder bore, increasing and decreasing the cylinder volume. You can watch the smaller piston in the port move inward or outward, as cylinder pressure increases or decreases. The displacement of the small piston and spring is dictated by the spring constant, which is in units of force per displacement (lbs/in). Lets assume that the pressure variations, as the cylinder volume increases and decreases, stay the same as when the cylinder was simply capped off. What happens when the spring constant is changed? As the cylinder volume decreases or increases, the small piston and spring move different lengths than before. However, with the assumption that the overall cylinder pressure increase or decrease never changed, only the spring travel changed. This is a simple model of an inlet or exhaust port.
Inlet And Exhaust Port Effectiveness
Why the analogy of the spring and piston in the inlet and exhaust port? The spring constant can be thought of as the port's effectiveness or capability. It will be a function of the port's shape, as well as it's cross sectional area. An assumption was made that said the increase and decrease of pressure in the cylinder remained the same, regardless of how much the small piston and spring moved. In other words the cylinder could only exert so much pressure and that was a function only of the crankshaft geometry and of the cylinder bore area. Regardless of what the spring rate (or port effectiveness) was, the cylinder volume could only produce the pressures that were obtainable when it was capped. The next statement should be viewed only in the context and assumptions of the previous paragraphs. The amount of volume displaced in the cylinder was the same regardless of the spring constant and the small piston's position in the port. So, extending the statement a little further for our purposes, the inlet and outlet port's effectiveness has nothing to do with the volume of charge displaced by the cylinder.
For the next step, add a second port (with piston and spring) to the capped cylinder assembly. This means a cylinder with two ports, each with a small piston and spring. However, this time two modifications will be made. One port will be fixed to allow the piston to move in one direction and the other port will be fixed oppositely. This means that as the crank rotates and the cylinder volume increases, the one port will allow the piston and spring to extend. As the cylinder volume decreases the other port will allow compression of the spring. As the crankshaft is rotated, each piston and spring will be extended or compressed. If the spring constants are changed in either of the ports, the extended or compressed dimension will be altered. This is a decent analogy of a cylinder with an inlet and exhaust port, one displaced by pressure and the other by vacuum. Again, the spring rate can be thought of as the port's effectiveness. The mechanical stops that prevent the piston and spring from moving are analogous to the valves closing off the port.
Cylinder Pressure and Torque
At this point, move from the pistons and springs set-up to a more conventional picture. A cylinder volume with an inlet and exhaust port. Each with a conventional shaped valve to control flow into and out of the cylinder volume. Keep the same assumption about the cylinder pressure increases and decreases remaining the same as when the cylinder volume was capped. Early on, I explained about torque and horsepower. Lets put a torque wrench on the snout of this crankshaft. Now when the crankshaft is rotated, we have capability to see cylinder pressure and torque, working together. Try to follow some typical valve timing rationale. As the cylinder volume increases, open one of the valves. When the piston starts moving back up the bore and decreasing the cylinder volume close that valve. Continue turning the crankshaft one full rotation until the volume once again starts decreasing. At that point, open the other valve. Continue turning until the volume is the smallest and close the valve. Go through that crankshaft rotation smoothly and watch the pressure gauge on the cylinder change. Note how the torque can change, depending on where in the rotation the valve is open. The goal is to open and close the valves throughout the crank rotations and keep the torque and cylinder pressure maximized. Watch what happens if the crankshaft is rotated slower or faster. The valve events will need to change for each case of different rotational speed. If you could use some sort of iterative process, for a given rpm, inlet and exhaust capability (effectiveness), and cylinder geometry, it would be possible to arrive at the optimum valve timing setting. This is for illustrative purposes only, because in reality very slow speeds will end up with a very wide range of valve timing that would enable maximum cylinder pressure.
Cylinder Filling, RPM, and Lag
The write-up has covered cylinder pressure, port effectiveness (using the spring constant idea), and torque (based on crank rotation and valve openings). The obvious next step is to gather these into one model. To do this, let's add realistic inlet and exhaust ports to the set-up, each with their own characteristics and cross-sections. Each port will now have it's own particular effectiveness. The goal is to rotate the crankshaft and optimize the valve events for maximum torque and cylinder pressure while a slow rotational speed is being utilized. If you change the inlet or exhaust port's effectiveness at this point, the torque and cylinder pressures do not deviate much. This is because the port is able to keep up with the displaced volume of the hand-rotated crankshaft. However, as the rpm is increased something different starts happening.
At this point, it is important to remember how flow is typically measured. It is in terms of flow rates. That is a unit of flow volume per a unit of time (cubic feet per minute, CFM). This means that for each volume of air displaced by piston movement for one crankshaft rotation, it becomes a flow rate when the rotations are measured with repect to time (revolutions per minute, rpm).
As the rpm is increased, the draw on the port becomes greater. As the charge is drawn or accelerated through the port, the inertial effects create a lag between the movement of the incoming air and the displaced air in the cylinder. Go back to the piston and spring analogy. The piston and spring will be displaced a particular distance, as a function of the spring constant. What happens when a damping action acts in conjunction with the spring constant giving the piston and spring a slight lag as the cylinder volume begins increasing or decreasing with crankshaft rotation? The piston and spring will not displace the same distance. This means that the lag is delaying the ports' response and will not respond to the complete displaced volume of the cylinder. In short, it moved less volume.
Step back and take a look at this. The previous paragraphs describe how the intake valve closing controls the pressure that gets trapped in the cylinder. However, the total cylinder pressure capability, for a given rpm, is not dictated by the intake closing, but rather by the inlet port capability. If the closing of the intake valve is a given for a particular cylinder volume, port configuration, and RPM, how can the cylinder pressure be increased? The amount of charge actually trapped has to be increased (or a better choice of words, the cylinder volume needs increased filling). For a given configuration, the only way to increase the cylinder filling is through the valve events. If the intake closing is fixed, the only alternative is to open the intake valve earlier.
Combine the lag effects and the cylinder filling characteristics and try to optimize the cylinder while the turning at higher, but constant, RPMs. Opening the intake valve earlier will increase the cylinder filling and therefore increase cylinder pressure capability. But there is another player that will make the earlier intake opening cause problems.
Cam Truth by Buddy Rawls, 10/2005
Introduction
More articles have probably been written about camshafts than any other engine component. To me, the camshaft, or more specifically the valve timing events are the most important aspect of an engine's ability to perform. This write-up is not going to describe how an engine works, by using text book explanations for the cycles in the 4-stroke naturally aspirated engine. It is intended to present the relationship of the camshaft to the engine combination and apply that relationship to engine performance characteristics. I will incorporate various lines of reasoning used by the media and enthusiasts, and how they apply to engine modifications. The intent is not to prove right or wrong, but to help provide a clearer understanding. I present this write-up based on my experience of modeling engine parameters to calculate power capability and flow requirements. As always, there are assumptions to simplify the subject. None of the thermodynamic properties, pressure wave phenomena, or combustion aspects will be covered in this write-up. In order to address the various ideas, an engine model will need to be visualized. The engine models are simple, however, I consider them to be a realistic approximation of the engine as a system, focusing on flow and valve timing requirements.
The Understandable Engine
Engine Modifications and Cylinder Pressure
First, let's look at what an engine does. The first inclination is to say that an engine produces power, typically noted as horsepower. This is not really the case. An engine produces torque (which is measured in terms of work on a dyno) and when applied over a unit of time (as in revs per minute), you get power. The formula that relates horsepower to torque is this: HP = Torque x RPM / 5252. The 5252 is not some sort of experimentally derived constant. It is simply a units conversion.
Let me explain in very simple terms: an engine moves or exchanges air; it is basically a pump. It's output directly relates to how much pressure is produced from the trapped charge in the cylinder as the piston travels up and down its bore . There are many things that go into this: crankshaft geometry, cylinder volume, RPM, inlet and exhaust port characteristics, and sealing capability just to name a few of the more important ones (to me). You can alter the breathing aspects and cylinder volumes and crankshaft geometry, but it all comes down to making cylinder pressure. The sole component of the engine that really controls cylinder pressure is the camshaft and its associated control of the valve events, regardless of inlet/exhaust capabilities and bottom end geometry.
Valve timing is made up of timing events measured lift per degree of crank rotation. Most conversations and articles always seem to focus on the valve duration and maximum valve lift. The thing that must be remembered, is that those lifts, durations, and lobe separation angles come from the timing events, and not the other way around. So when subjects tend to move toward specific durations and lobe separation angles, be aware, that unless you are talking about identical engines (geometry, cylinder volume, inlet and exhaust characteristics, etc.), the specific numbers and comparisons do not mean much. The subject needs to focus on cylinder pressure and not on whether a cam is classified as a racing or a street grind.
Almost every performance enthusiast understands that increased flow and/or increased cylinder volume gives increased power. However, not all increases in flow capability or engine size yield positive results. Sometimes a performance decrease occurs. The statement really needs to be reworded to this: increased flow and/or cubic inches gives increased power capability. There is a big difference. The revised statement demonstrates that performance gains are dependent on the set-up in some way.
Simple Cylinder Pressure Model
For the next portion, consider simple cylinder pressure models. Take a look at what happens as the crankshaft rotates and moves the piston up and down the cylinder bore. Imagine if you could cap off the top of the cylinder bore and install a pressure guage. What happens if you rotate the crank, moving the piston upward, decreasing the overall cylinder volume? Then what happens when the piston moves down, increasing the volume? As the volume changes, the pressure within the enclosed cylinder is increased or decreased. A decrease in volume will generate an increased pressure and a volume increase will generate a decrease in pressure (vacuum).
Now, incorporate a port on top of the cylinder bore. Inside the port, imagine a small piston with a spring that can extend or compress as it is pushed or pulled in the port. Now rotate the crankshaft. The piston moves up and down the cylinder bore, increasing and decreasing the cylinder volume. You can watch the smaller piston in the port move inward or outward, as cylinder pressure increases or decreases. The displacement of the small piston and spring is dictated by the spring constant, which is in units of force per displacement (lbs/in). Lets assume that the pressure variations, as the cylinder volume increases and decreases, stay the same as when the cylinder was simply capped off. What happens when the spring constant is changed? As the cylinder volume decreases or increases, the small piston and spring move different lengths than before. However, with the assumption that the overall cylinder pressure increase or decrease never changed, only the spring travel changed. This is a simple model of an inlet or exhaust port.
Inlet And Exhaust Port Effectiveness
Why the analogy of the spring and piston in the inlet and exhaust port? The spring constant can be thought of as the port's effectiveness or capability. It will be a function of the port's shape, as well as it's cross sectional area. An assumption was made that said the increase and decrease of pressure in the cylinder remained the same, regardless of how much the small piston and spring moved. In other words the cylinder could only exert so much pressure and that was a function only of the crankshaft geometry and of the cylinder bore area. Regardless of what the spring rate (or port effectiveness) was, the cylinder volume could only produce the pressures that were obtainable when it was capped. The next statement should be viewed only in the context and assumptions of the previous paragraphs. The amount of volume displaced in the cylinder was the same regardless of the spring constant and the small piston's position in the port. So, extending the statement a little further for our purposes, the inlet and outlet port's effectiveness has nothing to do with the volume of charge displaced by the cylinder.
For the next step, add a second port (with piston and spring) to the capped cylinder assembly. This means a cylinder with two ports, each with a small piston and spring. However, this time two modifications will be made. One port will be fixed to allow the piston to move in one direction and the other port will be fixed oppositely. This means that as the crank rotates and the cylinder volume increases, the one port will allow the piston and spring to extend. As the cylinder volume decreases the other port will allow compression of the spring. As the crankshaft is rotated, each piston and spring will be extended or compressed. If the spring constants are changed in either of the ports, the extended or compressed dimension will be altered. This is a decent analogy of a cylinder with an inlet and exhaust port, one displaced by pressure and the other by vacuum. Again, the spring rate can be thought of as the port's effectiveness. The mechanical stops that prevent the piston and spring from moving are analogous to the valves closing off the port.
Cylinder Pressure and Torque
At this point, move from the pistons and springs set-up to a more conventional picture. A cylinder volume with an inlet and exhaust port. Each with a conventional shaped valve to control flow into and out of the cylinder volume. Keep the same assumption about the cylinder pressure increases and decreases remaining the same as when the cylinder volume was capped. Early on, I explained about torque and horsepower. Lets put a torque wrench on the snout of this crankshaft. Now when the crankshaft is rotated, we have capability to see cylinder pressure and torque, working together. Try to follow some typical valve timing rationale. As the cylinder volume increases, open one of the valves. When the piston starts moving back up the bore and decreasing the cylinder volume close that valve. Continue turning the crankshaft one full rotation until the volume once again starts decreasing. At that point, open the other valve. Continue turning until the volume is the smallest and close the valve. Go through that crankshaft rotation smoothly and watch the pressure gauge on the cylinder change. Note how the torque can change, depending on where in the rotation the valve is open. The goal is to open and close the valves throughout the crank rotations and keep the torque and cylinder pressure maximized. Watch what happens if the crankshaft is rotated slower or faster. The valve events will need to change for each case of different rotational speed. If you could use some sort of iterative process, for a given rpm, inlet and exhaust capability (effectiveness), and cylinder geometry, it would be possible to arrive at the optimum valve timing setting. This is for illustrative purposes only, because in reality very slow speeds will end up with a very wide range of valve timing that would enable maximum cylinder pressure.
Cylinder Filling, RPM, and Lag
The write-up has covered cylinder pressure, port effectiveness (using the spring constant idea), and torque (based on crank rotation and valve openings). The obvious next step is to gather these into one model. To do this, let's add realistic inlet and exhaust ports to the set-up, each with their own characteristics and cross-sections. Each port will now have it's own particular effectiveness. The goal is to rotate the crankshaft and optimize the valve events for maximum torque and cylinder pressure while a slow rotational speed is being utilized. If you change the inlet or exhaust port's effectiveness at this point, the torque and cylinder pressures do not deviate much. This is because the port is able to keep up with the displaced volume of the hand-rotated crankshaft. However, as the rpm is increased something different starts happening.
At this point, it is important to remember how flow is typically measured. It is in terms of flow rates. That is a unit of flow volume per a unit of time (cubic feet per minute, CFM). This means that for each volume of air displaced by piston movement for one crankshaft rotation, it becomes a flow rate when the rotations are measured with repect to time (revolutions per minute, rpm).
As the rpm is increased, the draw on the port becomes greater. As the charge is drawn or accelerated through the port, the inertial effects create a lag between the movement of the incoming air and the displaced air in the cylinder. Go back to the piston and spring analogy. The piston and spring will be displaced a particular distance, as a function of the spring constant. What happens when a damping action acts in conjunction with the spring constant giving the piston and spring a slight lag as the cylinder volume begins increasing or decreasing with crankshaft rotation? The piston and spring will not displace the same distance. This means that the lag is delaying the ports' response and will not respond to the complete displaced volume of the cylinder. In short, it moved less volume.
Step back and take a look at this. The previous paragraphs describe how the intake valve closing controls the pressure that gets trapped in the cylinder. However, the total cylinder pressure capability, for a given rpm, is not dictated by the intake closing, but rather by the inlet port capability. If the closing of the intake valve is a given for a particular cylinder volume, port configuration, and RPM, how can the cylinder pressure be increased? The amount of charge actually trapped has to be increased (or a better choice of words, the cylinder volume needs increased filling). For a given configuration, the only way to increase the cylinder filling is through the valve events. If the intake closing is fixed, the only alternative is to open the intake valve earlier.
Combine the lag effects and the cylinder filling characteristics and try to optimize the cylinder while the turning at higher, but constant, RPMs. Opening the intake valve earlier will increase the cylinder filling and therefore increase cylinder pressure capability. But there is another player that will make the earlier intake opening cause problems.