VALVES

Function
Function of the exhaust valve is used for expelling the burnt gases from the engine cylinder. Function of the inlet valve is used for allowing fresh air from turbocharger or manifold entering the engine cylinder Both valves seals gases on compression and combustion periods

Valve cages
Exhaust valves are subject to arduous conditions, and require regular overhaul. To aid this, exhaust valves are often fitted in separate cages. This allows the exhaust valve to be changed and overhauled without removing the cylinder head. The cages have water cooling passages connected to the cylinder head cooling water.

 The cage is of cast steel. The cooled seats are made from a heat resistant molybdenum steel which may be stellite faced. The exhaust valve may be of a similar material or of a nimonic alloy. Inlet valves are subject to much less arduous conditions and are not usually fitted in separate cages.

Valve springs
Two different sized springs are fitted to aid positive closing of the valves. The reason for fitting two springs are that if one fails, the other will prevent the valve dropping down into the cylinder. The two springs have different vibration characteristics, so the incidence of resonance is reduced. (resonance is where two items vibrate at the same frequency thus the amplitude of the vibration is amplified.)

 Exhaust valves are designed to rotate in service. The reasons for this are to prevent uneven temperatures so it does not distort and leak by, and to help dislodge any build up of deposits on the valve and seat which may prevent the valve closing properly and lead to "hammering" of the seating faces. A mechanical method is generally used, and this is either the "rotocap" or the "turnomat". Winged rotators or spinners as used on the 2 stroke engine exhaust valves can also be used, but this entails using a ball bearing race between the spring carrier and the cover.

Rotorcap or turnomat

NON-POSITIVE VALVE ROTATOR Spring cap/retainer

Tappet
Tip cut
Clearance when valve seated

Retainer lock

Valve spindle

Spring
Valve guide

POSITIVE VALVE ROTATOR Bellville washer Cotter D Circlip Ramp Rotation

Section D-D D Valve springs Spindle

VALVE CLOSED POSITION VALVE OPENING POSITION

Top view

Valve cooling
Only exhaust valve since inlet valve working condition not severe, flowing gases assist cooling Hot gases burn valve and seat process is cumulative Heat transmitted thru seat (at closed position) and some thru stem

 Centre of valve head hottest. Problem of cooling thus valve cage obsolete except in large highly rate engines 3 common methods of cooling: valve cages cooling, cooled valve, air bled from air manifold and directed to valve another method is sodium-cooled valve

Temperature distribution on valves

200

250 320 300

360

400 450 470

410 360 374 463

Spindle
Cooling water outlet

Cooling water inlet

Cooling water outlet

Valve housing

Guide bush and spring retainer

Exhaust gas outlet

Cooling water inlet

Water cooled stem guide

Water cooled stem guide and seat

Water cooled exhaust valve

Advantages
Temperature of valve during operation is lower Due to above maintenance less Valve life last longer

Disadvantages
Required flexible connections troublesome Cooling medium must be clean as blockage may lead to distortion results manufacturing cost higher

Cooling media inlet Flexible connection

Cooling media outlet

Flexible connection Plug

Plug

Water cooled exhaust valve

Internal tube

Hollow valve stem and head

350 400oC

450

500oC

400 450oC

500 550oC 550 600oC 600 650oC

Water cooled stem guide

Water cooled stem guide and seat

Rocker or Tappet Clearances

Rocker or Tappet clearances refer to the clearance between the top of the valve spindle and the rocker arm. It is to ensure that the valve closes properly when it expands as it gets to operating temperature.

 Clearances are set according to manufacturers instructions, but usually done with the engine cold, and with the push rod follower on the base circle of the cam. (one way of ensuring this is to turn the unit being adjusted to TDC on the power stroke.)

 If the clearance is too small, then not only is there a chance that the valve will not close properly when it comes up to temperature, but it effectively will open early and close late. Conversely if the clearance is too large, then the valve will open late and close early

Suction and Exhaust Valves

Valve material
Inlet valve Exhaust valve
Good quality steel and can be heat treated
Good strength at high temperature Retain its properties after repeated heating to working temperature and cooling in air no tendency to air harden Having critical temperature above 800oC Resist hot and cold corrosion fuel No tendency to scaling at high temperature Must be easily forged or machined Capable of consistent and reliable heat treatment

Disassembling sequence
Set the valve spring detaching /attaching tool shown in the figure at right on the cylinder head. Turn the handle of this detaching /attaching tool in the direction to press the spring. Incidentally, when disassembling the valve spring or valve rotator without taking out the cylinder head, bring the piston to T.D.C position and carry out the foregoing steps.

Cautions for disassembly check and reassembly.

At the time of disassembly, carefully check the valve spring for any existence of crack and corrosion. Two valve spring shoe cotters are being used foe each suction/exhaust valve. At the time of reassembly, they should be used by a pair and more over to the same valve. (unless they are handle by a pair, the valve rod might be damaged due to inferior contact of the cotter part . When the valve rotator is detached, disassemble it and check its interior too.

Suction / exhaust valve grinding.

Perform the first time's valve grinding earlier the usual as indicated in Table of Periodical Checking given in section 8 and judging the situation, prolong the henceforth servicing interval. Prior to valve grinding, confirm the wear of valve guide and clearance between the valve guide and the valve rod that serve as criteria on valve working, compare these measured values with the corresponding values indicated in Table of Clearance and Wear Limit of major parts given in the manual, and proceed to grinding work upon replacement of the pertinent parts as required.

 Measure the dimension of contact of the seat part of valve and seat ring. And if this measurement is reaching the pertinent limit given, replace the parts involved with the new ones. Correct particularly the valve upon careful checking of it because if the valve head face becomes too thin, it will break and broken pieces will enter not only combustion chamber but the turbocharger, causing serious secondary damage. Elaborate execute valve grinding, applying grinding compound of proper quantity to the valve to be ground and using the suction /exhaust valve grinding tool.

Valve problems
Mechanical difficulties or corrosion and oxidation which lead to burning
Breakage Valve face and seat wear Face guttering Valve pounding or bouncing Shrouding of valves Corrosion and burning

Breakage
May occur in valve head. Due to poor design from strength or heat transfer standpoint. Of from abnormal temperature caused by poor seat contact due to deformation of parts, deposits or corrosion May also occur at stem-head junction. Due to heavy leads created by overspeed operation or abnormal pounding created from excessive valve lash or weak valve spring

Valve face and seat wear

Common with intake valves due to pounding, fretting and scuffing Not common with exhaust valve due to better materials and deposits at exhaust valve seat prevent intimate metallic contact between surface

Face guttering
Not corrosion but high temperature oxidation due to leakage of hot gases

Valve pounding or bouncing

Caused by too much valve lash and or weak springs May caused seat and valve face distortion and reduced valve life Bouncing reduced by increasing number of springs instead of one heavy and bigger diameter spring, by improving spring material and by means of hydraulic valve actuating gear

Shrouding of valves
Caused by repeated grinding and lapping. Valve lift remains constant but effective opening area reduced by amount of shroud Affect air or gas flow across valve due to less opening area and loss of stream lined flow Removed by seat cutter, machining and special grinding machines

Corrosion and burning

Serious exhaust valve problems. Corrosion accelerated by some lube oil additives in combination with certain fuel components and by combustion products. Increased by increased valve temperatures

 Corrosion and deposits on valve face and seat are accelerated by high-ash lube oil. Initially deposits make a smooth hard seat. But as deposits thickens, it partially crack off, leakage develops and valve temperature increased. Results is burning and ultimate failure. Corrosion on stem and head destroys and roughens surface of material results in fatigue failure.

MAINTENANCE

Doing overhauls according to the maintenance schedule or running hours Change the vales if necessary (before running hours) Taking care to valve tappet clearance

 Correct cooling system -L.O. pressure -cooling water (fresh water) Choose correct grinding or lapping paste

Conclusion
We should taking care about tappet clearance, valve rotator, valve spring, valve cage, cooling system, valve condition (surface area), valve seat and so on to the valve perform in high performance. And donning maintenance according maintenance schedule.

THE END
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