Improvement of Racing Engine Valve Spring Performance using 'ARMeD' Logic and the 'NOVA' Production Process

Due to rising costs related to the production, warranty and fatigue life requirements of high performance racing engine valve return springs, there exists a need to develop a comprehensive method of manufacturing these components. The functional characteristics and fatigue life of high performance racing engine valve springs are crucial to the overall success and total costs of such engines. The primary function of a valve return spring is to control the motion of the valve and return it to its starting position, while maintaining a preload. In this dissertation work, various concepts of performance and aspects of racing valve springs are discussed and studied with the goal of enhancing fatigue life and decreasing manufacturing and warranty costs through the utilization of the "NOVA" induction heating and hardening method and the "ARMeD" Logical approach of explaining such.;The experimental methods focus on developing and utilizing the NOVA induction heating and hardening manufacturing process as an adapted method to produce high performance valve springs. A detailed process flow is used to evaluate the expected and theorized gains in fatigue life enhancement and cost reductions. Statistical analysis methods and tools will be utilized in the course of this research to objectively substantiate the findings. Fatigue testing will be required using NOVA induction hardened racing valve springs made of ultra-high tensile material at varying mean and alternating stresses.;Using the ARMeD Logic approach, a theoretical discussion is presented to validate the experimental plans and elucidate the needs for the proposed NOVA method of racing spring manufacturing. The concept utilizing the NOVA method as a viable and superior alternative manufacturing process for these types of valve springs is explained using ARMeD Logic, as it relates to a macroscopic view of fracture mechanics. The manufacturing costs are evaluated to improve volume production efficacy.;The NOVA process flow and predictions of fatigue life performance S-N curves based are then presented as valid tools and methods for such applications. Experimental results, fatigue S-N models, theoretical justification and manufacturing cost models are used to finally illustrate how the NOVA process alleviates the issues associated with the current manufacturing process. The final goal is to demonstrate that NOVA can become a superior process in all regards for the manufacture of high performance racing engine valve springs.