LECTURE NOTES

ENT348
MECHANICAL SYSTEM DESIGN
Lecture 6
18/3/2014
CAM DESIGN
Dr. HAFTIRMAN
MECHANICAL ENGINEEERING PROGRAM
SCHOOL OF MECHATRONIC ENGINEERING
UniMAP
COPYRIGHT©RESERVED 2014

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 Delivery Levels of Assess
Study Week Course Content ment
Mode Complexity
Cam-follower systems
Cam terminology, SVAJ
diagrams, Fundamental law
of cam design, Simple
Harmonic motion, Cycloidal
Lecture
displacement or sine constant
6-7 acceleration, Critical extreme
position (CEP, and critical
path motion (CPM).

(7 hours)

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 CO2:
Ability to evaluate machinery
dynamics of a mechanical system.

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 OUTLINE
• Introduction
• Cam Terminology
• SVAJ diagrams
• Double-dwell cam design
• Single-Dwell Cam design
• Critical Path Motion
• Sizing The Cam-Pressure Angle and Radius of
Curvature
• Practical Design Considerations
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 Introduction
• A cam is a common mechanism element that
drives a matting component known as follower.
• The camshaft is driven by the engine.
• As the cam rotates, and the rocker arm in turn,
imparts a linear, reciprocating motion to a valve
stem.
• The rocker arm follower needs to maintain
contact with the cam surface to achieve the
desired motion.
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 CAM TERMINOLOGY
Types of Cams
1. Plate or disk cam This type of cam is formed on a disk or
plate.
The radial distance from the center of
the disk is varied throughout the
circumference of the cam. Allowing a
follower to ride on this outer edge gives
the follower a radial motion.

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 CAM TERMINOLOGY
Types of Cams
2. A cylindrical or drum

This type of cam is formed on a

cylinder.
A groove is cut into the cylinder, which
varies along the axis of rotation.
Attaching a follower that rides in the
groove gives the follower motion along
the axis of rotation.

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 CAM TERMINOLOGY
Types of Cams
3. A linear cam
This type of cam is formed on a
translated block. A groove is cut into
the block with a distance that varies
from the plane of translation. Attaching
a follower that rides in the groove gives
the follower motion perpendicular to the
plate of translation.

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 CAM TERMINOLOGY
Classification of Cam-follower
1. Type of follower motion (translating or
rotating).
2. Type of cam, radial, cylindrical, three-
dimensional.
3. Type of joint closure (force or form
closed).
4. Type of follower (curved or flat and
rolling or sliding).
5. Type of constraints (critical extreme
position (CEP). DR. HAFTIRMAN
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 Type of follower motion
System with an oscillating or rotating follower

Radial Cam

AN OSCILLATING
CAM-FOLLOWER

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 CAM TERMINOLOGY
Radial Cam

A TRANSLATING
CAM-FOLLOWER

The choice between these two forms of the cam-follower is

usually dictated by the type of output desired.
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 Follower Position

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 Type of joint closure
• Force closure requires an external force be
applied to the joint in order to keep the two
links, cam and follower, physical in contact.
• The force is usually provided by a spring.
• This force defined as positive in a direction
that close the joint, cannot be allowed to
become negative.
• The links have lost contact because a force-
closed joint can only push, not pull.
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 Radial Cam

Form closure
No external force is required. There are really two cam surfaces
in this arrangement, one surface on each side of the follower.
Each surface pushes, in its turn, to drive the follower in both
directions.
Figure shows track or groove cams that capture a single follower in the
groove and both push and pull onDR.the follower.
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 Conjugate cams

Radial Cam

Figure shows conjugate terms.

Two roller followers, attached to a common arm, are each pushed in
opposite directions by the conjugate cams.

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Type of follower Radial Cam

Part of the follower link that

contacts the cam

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 An axial cam

An axial cam whose follower moves parallel to the axis of cam

rotation. A face cam if open (face-closed) and a cylindrical or barrel
cam if grooved or ribbed (form-closed)
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 An axial cam

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 Part loader

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GRAPHICAL DISK CAM PROFILE DESIGN

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 IN-LINE KNIFE-EDGE FOLLOWER

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 IN-LINE ROLLER FOLLOWER

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 IN-LINE ROLLER FOLLOWER

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 TRANSLATING FLAT-FACED FOLLOWER

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 PIVOTED ROLLER FOLLOWER

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 PRESSURE ANGLE

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 GRAPHICAL CYLINDRICAL CAM
PROFILE DESIGN

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 MACHINING A CAM

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 ACTUAL CAM PERFORMANCE COMPARED TO
THEORETICAL PERFORMANCE

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 GENEVA MECHANISM

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 TYPE OF MOTION CONSTRAINTS

Two general categories of motion constraint;

1. Critical Extreme Position (CEP)
2. Critical Path Motion (CPM)

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 TYPE OF MOTION PROGRAM
The motion programs
1. Rise-fall (RF)
2. Rise-fall- dwell (RFD)
3. Rise-dwell-fall-dwell (RDFD)
All refer mainly to the CEP case of motion
constraint and in effect define how many
dwells are present in the full cycle of motion,
either non RF, one RFD, or more than one
RDFD.
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 TYPE OF MOTION PROGRAM
• For a rise-fall (RF) CEP motion, with no dwell,
you should really be considering a crank-
rocker linkage rather than a cam-follower to
obtain all the linkage’s advantages over cams
of reliability, ease of construction, and lower
cost.

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 SVAJ DIAGRAMS
• The first task faced by the cam designer is to select the
mathematical functions to be used to define the motion of
the follower.
• The easiest approach to this process is to linearize the cam,
i.e., unwrap it from its circular shape and consider it as a
function plotted on Cartesian exes.
• Plot the displacement function “s”, its first derivative
velocity ”v”, its second derivative acceleration “a”, and its
third derivative jerk “j”, all on aligned axes as a function of
camshaft angle θ.
• Consider the independent variable in these plots to either
time t or shaft angle θ, and the constant angular velocity ω
of the camshaft. θ=ωt

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 The specifications for a four-dwell cam that
eight segments (RDFDRDFD)

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 The specifications for a four-dwell cam that
eight segments (RDFDRDFD)

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 DOUBLE-DWELL CAM DESIGN CHOOSING
S V A J FUNCTIONS

• Many cam design applications require

multiple dwells. The double-dwell case is
quite common.
• Cam specifications such as this are often
depicted on a timing diagram as shown in
Figure, which is a graphical representation of
the specified events in the machine cycle.
• A machine’s cycle is defined as one
revolution of its master driveshaft.
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This simple example in Figure is a critical extreme position (CEP) case,
because nothing is specified about the functions to be used to get from
the low dwell position (one extreme) to the high dwell position (other
extreme).

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 Example 8-1
• Problem:
Consider the following cam design critical extreme position
(CEP) specification:
• Solution:
• Dwell : at zero displacement for 90 degrees
(low dwell)
• Rise : 25 mm in 90 degrees
• Dwell : at 25 mm for 90 degrees (high dwell)
• Fall : 25 mm in 90 degrees.
• Cam ω : 2π rad/s = 1 rev/s
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 The displacement (s)
diagram

Equation of a
straight line
y = mx + v =>
m is slope of the line b
is the y intercept θ
replaces the
independent
variable x. Kv is velocity
constant
s = Kv
Velocity during the rise,
v = Kv = constant
a =0 (acceleration)

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 THE FUNDAMNETAL LAW OF CAM
DESIGN
• Any cam designed for operation at other than very low
speeds must be designed with the following constraints:
The cam function must be continuous through the first
and second derivatives of displacement across the
entire interval (360 degrees).
• The jerk function must be finite across the entire
interval (360 degrees).
• Piecewise functions must have third-order continuity
(the function plus two derivatives) at all boundaries.
The displacement, velocity and acceleration functions
must have no discontinuities in them.

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 Simple Harmonic Motion (SHM)

𝒉 𝜽
𝑺 = 𝟏 − 𝒄𝒐𝒔 𝝅
𝟐 𝜷
𝝅𝒉 𝜽 h is the total rise or lift
𝒗= 𝒔𝒊𝒏 𝝅 θ is the camshaft angle
𝜷𝟐 𝜷 β is the total angle the rise
interval

𝝅𝟐 𝒉 𝜽
𝒂 = 𝟐 𝒄𝒐𝒔 𝝅
𝜷 𝟐 𝜷

𝝅𝟑 𝒉 𝜽
𝒋 = 𝟑 𝒔𝒊𝒏 𝝅
𝜷 𝟐 𝜷
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 Simple harmonic motion with dwells
has discontinuous acceleration

Problem
Consider the same cam design critical
extreme position (CEP) specification

Dwell : at zero displacement for 90

degrees (low dwell)
Rise : 25 mm in 90 degrees
Dwell : at 25 mm for 90 degrees (high
dwell)
Fall : 25 mm in 90 degrees.
Cam ω : 2π rad/s = 1 rev/s

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 Solution
1. Full-rise simple harmonic function
applied to the rise segment of our cam.
2. Velocity function is continuous, as it
matches the zero velocity of the dwell at
each end. The peak value is 160 mm/s at
the midpoint of the rise.
3. The acceleration function, however, is
not continuous. It has a half-period
cosine curve and has non zero values at
start and finish that are 2.0 m/s2
4. There are discontinuities in the
acceleration at each end of the interval.
5. This violates the fundamental law of
cam design and creates infinite spikes
of jerk at the ends of this fall interval.
This is also an unacceptable design.

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 Prescribed Follower Motion
• The unique feature of a cam is that it can impart a very distinct
motion to its followers. The motion of the follower depends on
the task required and can be prescribed to exacting detail.
• Once the follower motion is prescribed, it is convenient to
record it in a graphical form. A plot of follower displacement
versus time, or cam angular displacement, is termed a follower
displacement diagram. This diagram is indispensable in that
the follower motion and kinematics can be explored without
regards to the shape of the cam itself.
• The period of cam rotation where there is no follower motion
is termed a dwell.
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 Prescribed Follower Motion
• When the cam is rotating at a constant velocity, which
incorporates the over whelming majority of applications. Time
can be related to angular displacement and vice versa.
∆𝜽
𝝎=
∆𝒕
• 𝜷 is cam rotation during an interval of follower motion.
Rotation angle of cam during the rise or fall interval under
consideration (degree)
• T is the time consumed during an interval. Total time period
for the rise or fall interval under consideration.
𝜷 = 𝝎 𝑻𝒊

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 Prescribed Follower Motion
• H is the amount of follower rise, or fall during
an interval.
• To determine the required speed of the cam.
𝟏 𝒓𝒆𝒗
𝝎= 𝑇𝑖 = the total time for
𝑻𝒊
one cycle

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 A cam is to be used for a platform that will
repeatedly lift boxes from a lower conveyor
to an upper conveyor.
This machine is shown in Figure.
Plot a displacement diagram and determine
the required speed of the cam when the
follower motion sequence is a s follows:

Rise 2 in in 1.2 s
Dwell for 0.3 s
Fall 1 in in 0.9 s
Dwell 0.6 s
Fall 1 in in 0.9 s

1. Calculate the time for a Full cycle.

The total time to complete the full cycle is needed to determine the
required speed of cam

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 2. Calculate the required rotational speed of the cam

3. Determine the cam rotation for each follower motion interval

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 4. Plot the displacement diagram

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 CONSTANT VELOCITY

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 CONSTANT VELOCITY
• A cam is required for an automated transfer
mechanism. The cam follower must
rise out-ward 1.0 in. with constant velocity in 3.0 s.
dwell for 0.5 s.
fall with constant velocity in 2.0 s.
and then repeat the sequence.

• Determine the required speed of the cam and

graphically plot a follower displacement
diagram.
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Since fall occurs in less time and maximum velocity occur then

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 Dwell
Follower displacement s, (in)

Fall
Rise

0 3 3.5 5.5 Time (s)

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 CONSTANT VELOCITY
• A cam is required for a reciprocating follower
for a pick and place robotic arm mechanism.
The cam follower must
rise out-ward 0.75 in. with constant velocity in 1.4 s.
dwell for 2.3 s.
fall with constant velocity in 0.8 s.
dwell for 1.9 s.
and then repeat the sequence.

• Determine the required speed of the cam and

graphically plot a follower displacement
diagram.
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Since fall occurs in less time and maximum velocity occur then

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Follower displacement s, (in)

0.75

0 1.4 3.7 4.5 6.4 Time (s)

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 CONSTANT ACCELERATION

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 CONSTANT ACCELERATION
A cam is required for a shaker platform.
This platform is used to test the shipping
worthiness of packaged items. The cam
follower must
rise out-ward 1.0 in. with constant
acceleration in 0.7 s.
dwell for 0.2 s.
fall with constant acceleration in 0.5 s.
dwell for 1.9 s, and then repeat the sequence.

Determine the required speed of the cam

and graphically plot a follower
displacement
ENT348 Mechanical System
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Since fall occurs in less time and maximum velocity and acceleration
occur then

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Follower displacement s, (in)

0 0.7 0.9 1.4 3.3 Time (s)

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 HARMONIC MOTION

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 HARMONIC MOTION

A cam drive is used for a mechanism that

tests the durability of oven doors. The
cam follower must
rise out-ward 2 in. with harmonic motion in 1 s.
dwell for 0.5 s.
fall 2 in with harmonic motion in 1 s.
and dwell for 1 s, and then repeat the sequence.

Determine the required speed of the cam

and graphically plot a follower
displacement diagram.
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Since fall occurs in less time and maximum velocity and acceleration
occur then

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Follower displacement s, (in)

0 1 1.5 2.5 3.5 Time (s)

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 CYCLOIDAL MOTION

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 CYCLOIDAL MOTION

A cam drive is used for a mechanism incorporated

in a shoe-sewing machine. The cam follower
must

rise out-ward 0.5 in. with cycloidal motion in 0.7 s.

dwell for 0.2 s.
fall 0.25 in with cycloidal motion in 0.5 s.
dwell for 0.2 s.
fall 0.25 in with cycloidal motion in 0.5 s.
and then repeat the sequence.

Determine the required speed of the cam and

graphically plot
ENT348 Mechanical System
a follower displacement
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diagram.
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Since fall occurs in less time and maximum velocity and acceleration occur
then

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Follower displacement s, (in)

0.5

0.25

0 0.7 0.9 1.4 1.6 2.1 Time (s)

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 The SCCA family of double dwell functions

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ENT348 Mechanical System Mechanical Engineering Program
110
Design Sem 2-2013/2014 School of Mechatronic Engineering
 DR. HAFTIRMAN
ENT348 Mechanical System Mechanical Engineering Program
111
Design Sem 2-2013/2014 School of Mechatronic Engineering
 THANK YOU

DR. HAFTIRMAN
ENT348 Mechanical System Mechanical Engineering Program
112
Design Sem 2-2013/2014 School of Mechatronic Engineering