Design and 3D Modeling of Automotive Rocker Arm Using CATIA V5

Advancements in camshaft and valvetrain design have significantly improved engine performance over the past three decades; however, overhead valve (OHV) engines still rely on rocker arms, pushrods, and lifters to actuate intake and exhaust valves. The rocker arm is subjected to cyclic loading, high contact stresses, and elevated temperatures ranging from 40–500 °C, requiring materials that combine low weight, reduced friction, high fatigue life, and cost-effectiveness. Conventional materials such as structural steel, forged steel, stainless steel, tungsten, and aluminum alloys are increasingly being replaced or supplemented by lightweight fibre-reinforced polymer (FRP) composites to improve durability and reduce inertia. This study presents a comparative static structural and fatigue analysis of rocker arms manufactured from structural steel, aluminum alloy, and composite materials. Design enhancements, including needle-bearing fulcrums and roller tips, are incorporated to reduce friction and wear. Finite Element Analysis (FEA) is performed to evaluate stress distribution, deformation, safety factors, and fatigue life under operational loading. Failure modes such as yielding, crack initiation, and delamination are assessed to determine material suitability. Results demonstrate the potential of composite rocker arms as lightweight and high-strength alternatives to traditional metallic components, supporting their application in next-generation valvetrain systems with improved performance and reliability.