Abstract: A method of producing a cam lobe piece of an assembled camshaft in a valve operating system for an internal combustion engine. The method comprises (a) forming a profile of the cam lobe piece by upsetting a material under forging to obtain an intermediately formed body; (b) piercing a central portion of the intermediately formed body to form a shaft bore; and (c) ironing an inner peripheral surface of the pierced intermediately formed body to form unevenness at the inner peripheral surface, all accomplished by cold working. The material at the forming the profile of the cam lobe piece has a first section located on a side of a cam nose of the cam lobe piece, and a second section located longitudinally opposite to the first section. The material has a thickness which gradually increases in a direction from the second section to the first section.

Abstract: An assembly provides metallic ends to a composite shaft and a method of fabricating such an assembly. The composite shaft is preferably comprised of reinforced fibers. A metallic inner sleeve is positioned in the cavity of one end of the shaft. A metallic outer sleeve is positioned around the end of the shaft having the inner sleeve therein. The outer sleeve may include structural features, such as dimples, that ensure a stable connection between the sleeve and the shaft. The sleeves are compressibly forced onto the shaft, thereby forming the assembly. Both sleeves are metallic, and therefore provide a surface onto which weld joints can be formed. A preferred method of assembly includes the steps of expanding the inner sleeve and compressing the outer sleeve against the shaft.

Abstract: The invention relates to a method for producing a built shaft, whereby at least one part (2), particularly a cam, is mounted on the shaft (1), particularly a camshaft, whereby the shaft (1) is inserted into an opening (3) of the part (2). Before mounting the part (2), the shaft (1) is stretched by means of a stretching and tightening device (7′, 7″) in such a manner that an original diameter (D1) in the area of at least one fastening location (4) is reduced to a diameter (D4). Afterwards, the part (2) is slid onto the shaft (1) and up to the fastening location (4) on the shaft (1). The stretching and tightening device (7′, 7″) is then loosened once again thereby enabling the diameter of the shaft (1) to enlarge once more towards its original diameter (D1). The part (2) is firmly fastened at the fastening location (4) by interference fit in both an axial as well as rotationally fixed manner.

Abstract: The invention relates to a method for assembling a camshaft by using a shaft (10) and a plurality of cams (21-26) comprising respectively an opening for the shaft. According to the invention, the cams are disposed in a tight manner in a storage element (40), in such a way that they are orientated towards each other in a predefined rotative position, the openings thereof for the shaft being orientated in a coaxial manner. The shaft is then introduced into the cam packet and arranged consecutively with respect to each individual cam by displacement in the longitudinal direction thereof. The cams are secured one after the other on the shaft. The required rotation of the cams can be obtained in a simple manner by longitudinal displacement of the shaft and also by optionally rotating the shaft at a certain angle.

Abstract: Internal combustion engine performance can be enhanced by precise cylinder firing. To accomplish this objective, a preferred billet camshaft rebuilding method provides removing and replacing the distributor drive gear on the camshaft for precise alignment therewith. The method also demonstrates the detailed steps required to carry out the camshaft rebuilding process and the manufacture of a one-part distributor drive gear. An alternate method of using a two-part distributor drive gear on a camshaft is also described for camshafts having an interior distributor drive gear.

Abstract: A variable camshaft assembly has a first cams 18a, 18b that can be moved relative to a second cam 16. The assembly comprising a tube 14 fast in rotation with the first cam 18 and rotatably supporting the second cam 16 and a drive shaft 12 disposed within the tube 14 and coupled for rotation with the second cam 16 by means of a connecting pin 20 that passes with clearance through a hole 24 in the tube 14. The connecting pin is a hollow pin 20 that is a sliding fit in the second cam 16 and that is expanded in situ to form an interference with the drive shaft 12.

Abstract: A camshaft assembly and method of making a camshaft assembly is disclosed. Each of the cams includes a lobe boss portion that defines the cam lift profile, and a base portion that provides a surface for joining the cam to the shaft. In contrast to conventional ring-type cams, the base portion of the cam does not circumscribe the outer surface of the shaft, but instead extends only part way around the circumference or periphery of the shaft. This allows for radial mounting of the cams at virtually any timing angle, and permits the use of simple techniques for joining the cams to the shaft, including capacitance discharge welding. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Abstract: A method and apparatus for machining workpieces with rotationally symmetrical surfaces, for example crankshafts, by which the setting and idle times are minimised, transposition of the workpiece to another machine is avoided, and both large batch sizes and also small numbers of items are economically machined. Machining of the workpiece is effected both by a method in which the machining speed is produced primarily by the rotation of the workpiece, and also by a method in which the machining speed is achieved primarily by the rotation of the tool.

Abstract: The invention relates to a method for producing cams (1) for a camshaft. The cams are produced by bending together the ends of long profile strips (4) or by bending and putting together several pieces of profile strips in a circumferential direction. Cams produced in such a way are preferably welded onto the shaft. The invention also relates to suitable welding methods such as resistance welding, laser-beam or electron-beam welding and corresponding devices.

Abstract: A process and system for manufacturing a built-up camshaft by which the operational safety of the camshaft is ensured in a simple manner in any engine operation and the camshaft can arbitrarily be adapted to abutments which have different positions because of the individual engine construction. At least one cam is pushed onto a hollow shaft, after which the hollow shaft is expanded between the two faces of the cam which extend transversely with respect to the longitudinal course of the hollow shaft and at the respective bearing point by means of a highly pressurized pressure fluid. This fluid is delivered by a lance-shaped probe introduced into the hollow space of the shaft. On the one hand, a press fit occurs between the cam and the hollow shaft and, on the other hand, a bulging of the bearing point of the hollow shaft occurs which bridges the distance between the hollow shaft and the abutment.

Abstract: A method of producing a cam lobe piece of an assembled camshaft in a valve operating system for an internal combustion engine. The method comprises (a) forming a profile of the cam lobe piece by upsetting a material under forging to obtain an intermediately formed body; (b) piercing a central portion of the intermediately formed body to form a shaft bore; and (c) ironing an inner peripheral surface of the pierced intermediately formed body to form unevenness at the inner peripheral surface, all accomplished by cold working. The material at the forming the profile of the cam lobe piece has a first section located on a side of a cam nose of the cam lobe piece, and a second section located longitudinally opposite to the first section. The material has a thickness which gradually increases in a direction from the second section to the first section.

Abstract: A modular camshaft assembly having an elongated shaft, at least one cam lobe assembly, at least one spacer assembly, and a cam adapter assembly is disclosed. Each cam lobe assembly is selectively secured to the elongated shaft. Each spacer assembly is secured to the elongated shaft, wherein the spacer assembly is selectively positioned adjacent the cam lobe assembly. The cam adapter assembly is secured to the elongated shaft and adapted to connect the modular camshaft assembly to a drive assembly.

Abstract: A device and method for joining fitting parts provided with a passage opening on hollow profiles through partial expansion of the hollow profiles at the location of the fitting parts is provided. The fitting parts are slid on with the passage openings and are held in position by means of fluid high internal pressure expansion of the hollow profile. The device includes an expanding lance, which can be slid into the hollow profile and exhibits an axial borehole for the purpose of guiding the pressure fluid. The axial borehole is connected to a fluid high pressure generating system and exhibits a cross channel with an outlet for the pressure fluid in the direction of the hollow profile location to be expanded. The shell surface of the expanding lance exhibits sealing elements that are spaced apart and that define the outlet so as to seal axially on both sides against high pressure.

Abstract: A control cam or a gear wheel having a plurality of layers of flat material placed one on top of the other. Each of the layers of flat material is of a multi-part form with partition lines that extend in a direction of planes over the layers of material. At least some of the partition lines of neighboring layers of the flat material are offset in relation to one another. The partition line of a layer of flat material is arranged so that in both circumferential directions it lies approximately equally spaced in relation to a partition line of a neighboring layer of flat material.

Abstract: A cam with a bore that has a funnel-shaped core-insertion section. To ensure that the cam will rest more securely against the core and remain more precisely centered, the section (5) comprises at least two mutually aligned conical extents (6 & 7), each expanding outward at a different apical angle.

Abstract: A method of manufacturing a camshaft used in an internal combustion engine. The method of manufacturing the camshaft produces a camshaft which has reduced weight and added wear resistance at a lobe of the camshaft. The camshaft is manufactured to provide increased efficiency of the internal combustion engine. The method of making the camshaft includes mixing wear resistant material with a base material and metering the mixture into a rotating die. The rotating die rotates at a predetermined speed and forces the wear resistant material to the outer surface of the lobes.

Abstract: A method of manufacturing a camshaft used in an internal combustion engine. The method of manufacturing the camshaft produces a camshaft which has reduced weight and added wear resistance at a lobe of the camshaft. The camshaft is manufactured to provide increased efficiency of the internal combustion engine. The method of making the camshaft includes mixing wear resistant material with a base material and metering the mixture into a rotating die. The rotating die rotates at a predetermined speed and forces the wear resistant material to the outer surface of the lobes.

Abstract: A method of attaching and adjusting first and second members includes providing a first member having an outer surface and a second member. The second member is affixed to the outer surface of the first member at a desired axial position along the length of the first member and in a desired angular orientation. Subsequent to affixing the second member to the first member, the shape and/or dimensions of the second member is adjusted by increasing the density of at least a region of the second member. The densification may be accomplished by, for example, a mechanical working technique such roller burnishing, coining, sizing, shot peening, or laser impacting. In one embodiment of the invention, the method may is adapted to the production of combustion engine camshafts from separately provided camshaft tubes and cam lobes.

Abstract: A multi-valve internal combustion engine having a plurality of valves having skewed axes that are operated by cam lobes of a single cam shaft. The cam shaft operates the valves through rocker arms each of which are pivoted independently about axes that are skewed relative to the cam shaft axis so as to minimize bending stresses on the valve during its actuation. This also avoids scuffing between the rocker and the valve stem. At the same time, good contact is maintained between the cam lobe and the follower surface by machining the cam lobe so that it will have a slight concavity at least in its tip portion so as to ensure constant line contact with the follower.

Abstract: Encapsulated spark plugs improve combustion control in spark ignited engines. The present invention improves reliability and life of an encapsulated spark plug. A spark plug shell has a connection region and an orificed region, and a tip portion. The present invention provides improved heat transfer from the tip portion through the orificed region to the connection region. An access orifice provides access to set an electrode gap.

Abstract: A camshaft used in an internal combustion engine which has reduced weight and added wear resistance at a lobe of the camshaft. The camshaft is provided to add increased wear resistance and reduced weight to the internal combustion engine for increased efficiency of the internal combustion engine. The camshaft includes wear resistant material at the surface of the lobe of the camshaft. The wear resistant material is distributed on the outer surface of the lobe and incorporated into the base material.

Abstract: A process is provided for the production of a cam to be joined to a hollow shaft to form a camshaft. In order to make the cam suitable for stable long-term operation on the camshaft, the internal compressive stresses achieved in the cam track before the joining of the cam to the camshaft being so high that the tensile stresses resulting from joining are permanently overcompensated, it is provided that the material selected for the cam is a steel in which the carbon can be dissolved easily as cementite in the pearlite and martensite or is in the form of a fine composite carbide. The cam, which is composed of a hardenable steel, should be fully hardened and, during tempering in the hardening operation, the basic hardness should be set in a range of between 25 and 40 HRC. The cam should then be edge-zone-hardened in a two-stage heating process by induction hardening at a medium frequency of 10-35 kHz, after the preheating stage of the heating process, the introduction of heat being interrupted for 0.3-1.

Abstract: A process and system for manufacturing a built-up camshaft by which the operational safety of the camshaft is ensured in a simple manner in any engine operation and the camshaft can arbitrarily be adapted to abutments which have different positions because of the individual engine construction. At least one cam is pushed onto a hollow shaft, after which the hollow shaft is expanded between the two faces of the cam which extend transversely with respect to the longitudinal course of the hollow shaft and at the respective bearing point by means of a highly pressurized pressure fluid. This fluid is delivered by a lance-shaped probe introduced into the hollow space of the shaft. On the one hand, a press fit occurs between the cam and the hollow shaft and, on the other hand, a bulging of the bearing point of the hollow shaft occurs which bridges the distance between the hollow shaft and the abutment.

Abstract: A method for manufacturing a camshaft by inserting a hollow shaft 3 made of steel into an axial hole 400 of a cam lobe 4 made of a sintered alloy, by expanding the hollow shaft 3 by inserting a mandrel 1 into the hollow shaft 3, and by joining and fixing the expanded hollow shaft 3 and the cam lobe 4 while avoiding the constriction that might otherwise be caused by the retraction of the mandrel 1 inserted, of the expanded hollow shaft 3. The method includes an expanding step using a diverging long face 200, which is so formed on the leading head of the mandrel 1 as to diverge at an angle of about 8 to 30 degrees with respect to the axis toward the trailing end, and a bulging portion 2 formed to lead from the diverging face 200; and an expanding step using the bulging portion 2 of the mandrel 1 and a converging short face 201 which is formed so as to lead from the bulging portion 2 and to converge at an angle of about 8 to 30 degrees with respect to the axis toward the trailing end.

Abstract: A device for holding sintered cams during their binding on a tube by expansion of the tube, including, for each cam, two blocks intended for enclosing the cam in housings complementary to the cam contour. The dimensions of the housings are chosen so that the play between the housings and the largest cam within a predetermined tolerance range is as close to zero as possible by excess, the two blocks being provided to bear against each other whatever the dimensions of the cam within the tolerance range.

Abstract: A process for manufacturing a built-up camshaft by which the operational safety of the camshaft is ensured in a simple manner in any engine operation and the camshaft can arbitrarily be adapted to abutments which have different positions because of the individual engine construction. At least one cam is pushed onto a hollow shaft, after which the hollow shaft is expanded between the two faces of the cam which extend transversely with respect to the longitudinal course of the hollow shaft and at the respective bearing point by means of a highly pressurized pressure fluid. This fluid is delivered by a lance-shaped probe introduced into the hollow space of the shaft. On the one hand, a press fit occurs between the cam and the hollow shaft and, on the other hand, a bulging of the bearing point of the hollow shaft occurs which bridges the distance between the hollow shaft and the abutment.

Abstract: A method for making a multiple piece crankshaft from a shaft and a crankpin is disclosed. A notch is first machined on an intermediate section of the shaft such that the notch has a length slightly less than the length of the crankpin. Mating surfaces are then formed on the shaft at opposite ends of the notch. Thereafter, the crankpin is positioned on the mating surfaces on the shaft so that the crankpin is parallel to and spaced from an axis of the shaft. The ends of the crankpin are then secured to the mating surfaces formed on the crankshaft and a portion of the intermediate section of the shaft is then removed by machining. A counterweight is finally positioned over each end of the crankpin at its juncture with the main shaft and secured to the crankpin and shaft thereby forming the crankshaft. Alternatively, the crankpin is positioned on mating surfaces formed on the counterweights and fasteners then secure the crankpin, counterweights and main shaft together.

Abstract: A device for holding sintered cams during their binding on a tube by expansion of the tube, including, for each cam, two blocks intended for enclosing the cam in housings complementary to the cam contour. The dimensions of the housings are chosen so that the play between the housings and the largest cam within a predetermined tolerance range is as close to zero as possible by excess, the two blocks being provided to bear against each other whatever the dimensions of the cam within the tolerance range.

Abstract: A hollow cam shaft is composed of a hollow shaft having an inner hollow portion and an end piece which is pressure-welded to at least one end of the hollow shaft. The end piece comprises an end member which is pressure-welded to the one end of the hollow shaft and an enclosure member extending from the end member in an axial direction thereof so as to be inserted into the inner hollow portion of the hollow shaft at a time of pressure welding to define an enclosure space in the inner hollow portion of the hollow shaft. The enclosure member comprises a sealing portion having an outer shape substantially the same as an inner shape of the hollow shaft and a connection portion connecting an end surface of the end member of the end piece and the sealing portion so as to define said enclosure space between the enclosure member and the hollow shaft into which a burr generated at the pressure welding time is enclosed.

Abstract: A method of manufacturing a camshaft comprises the first step of casting a blank defining a central shaft, concentric journal bearings and eccentric cam lobes, the cam nose region between the journal bearing at the driven end of the camshaft and the adjacent cam lobe being cast in the same non-circular shape as the cam lobe but with smaller dimensions. The cam nose and the cam surface of the first cam lobe are then ground. Preferably, the cam lobe surface and the cam nose are ground at the same time as one another by means of a shaped grinding wheel having a cylindrical portion for grinding the cam surface and a narrower contoured portion of larger diameter at one end for grinding the cam nose.

Abstract: The invention relates to a process for fastening components on a hollow shaft (1), during which process the components (21, 22, 23), exhibiting an opening, are put into specified positions on the hollow shaft (1) and for the purpose of fastening components (21, 22, 23) the hollow shaft (1) is expanded by introducing a pressure medium. Support matrices (3) are arranged only between the components (21, 22, 23) for the purpose of bracing the regions of the hollow shaft (1) between the components (21, 22, 23) during the expansion operation.

Abstract: A method for simultaneously hardening a group of cams on a camshaft comprises first heating the group of cams at low power for at least one heating interval, then pausing the heating for a pause interval during which no power is applied to the group of cams, and then subsequently heating the group of cams at high power for one heating interval. The pause intervals, during which no power is applied to the group of cams, are sufficient as to allow heat stored in the cams to distribute uniformly throughout the cams. Each group of cams is hardened by a linear inductor and the regions of the camshafts that are not to be hardened are shielded by a cooling device.

Abstract: A device and method for joining fitting parts provided with a passage opening on hollow profiles through partial expansion of the hollow profiles at the location of the fitting parts is provided. The fitting parts are slid on with the passage openings and are held in position by means of fluid high internal pressure expansion of the hollow profile. The device includes an expanding lance, which can be slid into the hollow profile and exhibits an axial borehole for the purpose of guiding the pressure fluid. The axial borehole is connected to a fluid high pressure generating system and exhibits a cross channel with an outlet for the pressure fluid in the direction of the hollow profile location to be expanded. The shell surface of the expanding lance exhibits sealing elements that are spaced apart and that define the outlet so as to seal axially on both sides against high pressure.

Abstract: A method of making a hollow shaft having multiple functional elements arranged along the axis of an inner shaft tube is provided. Several multiple shafts equipped with functional elements may be joined by expansion using probes inserted into the shafts and connected to a high pressure generator. In addition, a method of providing functional elements to an inner tube wherein the individual non-round functional elements have annular projections concentric to the base circle is provided, where the internal diameter of the functional elements is slightly larger than the external diameter of the shaft tube. The functional elements have an annular region on their lateral edges of approximately half the wall thickness that complements the adjacent non-round functional element to achieve a full wall thickness and the annular projections are produced by re-formation of the profile tube.

Abstract: A method of producing and stacking components from individual layers which are punched, cut or the like out of a hardened material strip. According to the method, layers are removed from a hardened material strip, the removed layers are pressed back into the material strip and pressed out of the latter in a subsequent station (ii). They are then inserted into a stack magazine in which the individual layers are centered and assembled to form a component, the component then being removed from the stack magazine.

Abstract: A method is described for manufacturing a multi-component camshaft assembly having an internal mechanism for enabling relative angular movement of individual cams of the assembly. In the invention, the cam surfaces are machined after the individual components of the camshaft assembly have been assembled to one another.

Abstract: A method for making a lightweight composite camshaft, includes the steps of providing at least one lightweight cam element having a lobed outer surface and a hub with a cylindrical bore, at least a portion of the hub not being radially occluded by the outer surface; providing at least one lightweight journal element having a cylindrical outer surface and a hub with a cylindrical bore, at least a portion of the hub not being radially occluded by said outer surface; providing a hollow cylindrical tubular shaft member having a diameter sized to form a snug sliding fit in the hubs of the cam element and the journal element; positioning the cam and journal elements on the shaft in required axial and radial orientations; and applying means, on the hub of each element and that portion of the shaft which is in registry with the hub, for establishing a permanent interlock to fix each element in its required axial and radial orientation on the shaft.