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Eccentric Cam & Guided Roller Follower Assembly (2 Bodies)
Non-conformal Hertzian line contact between a case-hardened 100Cr6 eccentric cam lobe (R = 28 mm) and a guided cylindrical roller follower (R = 18 mm) under 13.75 kN valve-train preload.
In heavy-duty diesel valvetrains and fuel-injection pumps, convex-on-convex contact between the cam lobe crest (R1 = 28 mm) and the roller follower (R2 = 18 mm) produces extreme Hertzian contact pressures approaching 2 GPa. Using 2 disconnected B-Rep meshes (bonding = 0, mesh components = 2), this model resolves the concentrated Hertzian pressure spike at the tangent crest and the subsurface von Mises stress core inside both case-hardened 100Cr6 components.
1. Geometry & FEA Mesh
- •2 disconnected B-Rep solids (mesh components = 2): eccentric drive cam (R = 28 mm centered at y = +4 mm, shaft bore R = 10 mm at origin, width b = 12 mm) and profiled roller follower (contact arc R = 18 mm centered at y = +50 mm, width b = 12 mm).
- •Material: case-hardened bearing steel 100Cr6 / AISI 52100 / ШХ15 (E = 210 GPa, ν = 0.29, ρ = 7850 kg/m³).
- •Independent tetrahedral meshes: 11,450 elements, 3,114 nodes, and 9,342 DOFs.
- •Unilateral frictionless Mortar contact along the tangent line at (x = 0, y = 32 mm).
2. Loads & Boundary Conditions
- •Inner shaft bore of the eccentric cam (R = 10 mm) fixed in all directions (Ux = Uy = Uz = 0).
- •Vertical tappet guide flats of the roller follower (x = ±12.73 mm) constrained horizontally (Ux = 0), with rear faces held axially (Uz = 0).
- •45.0 MPa downward pushrod/valve-spring pressure (13.75 kN total force along -Y) applied to the top thrust face of the follower (y = +62 mm).
3. Simulation Results & Findings
- ✓Peak Hertzian contact pressure p_contact = 1,901.7 MPa along the line of tangency between the R = 28 mm cam crest and R = 18 mm roller.
- ✓Peak subsurface equivalent von Mises stress σ_vm = 922.1 MPa beneath the contact line.
- ✓Maximum vertical elastic approach |u| = 0.0413 mm at the top thrust face of the guided follower.
Powertrain engineers use WebCAE to analyze non-conformal cam-roller contact pressures and subsurface pitting resistance directly on B-Rep CAD geometry.
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