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Posts Tagged ‘Fail’

There are several valves that play a critical role in the efficient operation of your vehicle. For example, intake valves allow fuel into each cylinder’s combustion chamber. Exhaust valves allow vapors to exit the chambers following the combustion process. When problems form with the valves, your engine may suffer performance issues, including misfires and compression leaks. It’s important to have such problems addressed quickly to preserve your engine’s performance.

With that in mind, we’ll answer the most common questions people ask about their vehicles’ valves. The following should give you a better understanding regarding why they’re important, the issues that affect them, and the best approach toward resolving problems.

“What Causes Valves To Fail?”

Like all components, valves suffer wear and tear over tens of thousands of miles. If you drive your car far enough, they’ll eventually need to be replaced. However, they can fail long before they wear down due to burning or breaking.

Valves perform their jobs under extremely high temperatures. Exhaust valves run exceptionally hot (up to 1,400 degrees Fahrenheit) because they are exposed to the vapors that result from the combustion process. These high temperatures make them especially susceptible to burning.

When the valves burn, the metal become less sturdy. It’s not uncommon for them to suffer fatigue, causing pieces to break off. When this occurs, a compression leak develops.

“What Happens During A Valve Job?”

This type of repair work involves removing the cylinder head to expose the failing valves and guides. The more thorough repair shops will completely dismantle the cylinder head so the individual components can be cleaned and inspected. If cracks are identified, the entire head is either fixed or replaced (cracks are serious because they allow coolant to seep into the combustion chamber).

Next, the guides are replaced since they are usually worn past the point of effectiveness. The valves are either refaced if they’re still usable, or replaced.

“How Much Does This Type Of Work Cost?”

The repair bill can range from a few hundred dollars to several thousand. A lot depends on the type of engine in your vehicle and the type of repairs needed. For example, fixing a single valve in a standard 4-cylinder might cost under $400, including the labor. On the other hand, replacing multiple valves, fixing a crack head, and performing related repairs on an import can drive the bill upward.

“What Is A Leakdown Test?”

A leakdown test is used to find compression leaks from your cylinders’ combustion chambers. It identifies whether your cylinders are sealing properly and if they’re not, measures the percentage leakage. It’s worth noting that all engines suffer a degree of compression leakage. Even the best engines leak up to 10 percent of their compression. If a leakdown shows a compression loss of 30 percent or more, have a mechanic check your intake and exhaust valves.

“What Other Problems Can Affect Valves?”

Besides burning, breaking, and suffering normal wear and tear, your engine’s valves can also become bent. This can occur for several reasons, but often happens due to a broken timing belt. The belt breaks and sends the cylinder’s piston crashing into the valve. If a significant amount of damage results, the valve will need to be replaced. If the damage is minor, it can be refaced and reinstalled.

Engine valves receive far less attention than they deserve. They fill a role without which your vehicle could not operate efficiently. By sealing the combustion chamber, and opening at the precise moment to allow fuel to enter and gases to exit, your intake and exhaust valves perform a critical function. As such, when problems occur, they should be addressed quickly.

Repairing these components can be expensive, and becomes more so with the extent of the damage (i.e. cracks, breaks, etc.). However, neglecting the problem practically ensures it will be more costly to fix down the road.

New product development and innovation is much more difficult and time consuming than most other business activities. Automotive rapid prototyping greatly enhances learning speed and reduces the risk of new automotive parts development.

Historically, the automotive industry has been using rapid prototyping as an important tool in the automotive parts design process. The extremely fast-paced automotive design cycles require an extremely fast prototyping system which can produce car parts fast and inexpensively.

The main objective of automotive prototyping is to learn quickly: how a new automotive product behaves in its natural working environment, before transferring the prototype to the production line. Many times, mistakes are learned only after a new automotive part is launched. This is the main explanation for poor automotive parts design, from product mismatch, poor engineering and function or finish, and overpriced production. In order to accelerate the learning curve, before these costly automotive prototyping mistakes are made, one must accelerate and facilitate feedback loops from tests in the lab and market trials.

Automotive Manufacturing Technologies

Working with an assortment of rapid prototyping equipment, automotive prototyping engineers utilize the most advanced 3D printers, in their quest for perfect form, function and utility. Working in advanced manufacturing centers, the automotive engineers use the technology to verify what they are doing, and, equally important, to save tremendous amounts of time, and money.

Automotive Rapid Prototyping Compresses Development Time

The advantages of using 3D rapid prototyping model creation versus viewing a cad/cam model on a computer screen are palpable. Automotive parts engineers get together discuss the pros and cons of a rapidly produced automotive parts model and discuss the pros and cons of the design, as they pass it around, twisting and viewing the prototype, and decide if that is what they had in mind. This way, problems get solved up front, before going to the assembly line! Once determined that the automotive prototype design is a go, the model can then be sent to a die maker.

Automotive Prototyping and the Die Maker Process

The die maker cannot use model to make the die, but because they have it in their hand and can look at it and feel it, they can determine where the parting lines will be and exactly how much steel they will need to produce it. The timing of the die process is greatly compressed.

Examples of Automotive Rapid Prototype Parts

· Car Engine parts

· Engine castings and parts

· Auto Body Components

· Auto Mechanical parts

· Car Dashboards

· Car Handles and Knobs

· Car Trim parts

Fail first Paradox in Automotive Rapid Prototyping

The automotive rapid prototyping paradox is to fail earlier rather than later. By failing earlier, the design engineers surprisingly succeed in accelerating the project; this greatly reduces development cost risk. By considering all automotive prototype failures as learning experiments, the engineer has much less stress, knowing that they are practicing the old adage, that success comes from ninety-nine percent failure and introspection.