Cam and Follower

Mechanism
Prof Sumit Suresh Malusare
Finolex Academy Of Management & Technology, Ratnagiri

Prof. Sumit S Malusare, FAMT,Ratnagiri

Classification of cams
According to shape According to follower According to method
motion of constraints
Wedge cam DRDR cam Spring loaded
Radial cam DRRD cam Positively constrained
Globoidal cam RRR cam
Cylindrical
Conical
Spherical
3 Dimensional
Inverse

Prof. Sumit S Malusare, FAMT,Ratnagiri

Types of cam

Prof. Sumit S Malusare, FAMT,Ratnagiri

Prof. Sumit S Malusare, FAMT,Ratnagiri
Classification of Follower
According to surface of According to type of According to location
contact movement
Knife edge Translatory Radial
Flat faced Oscillatory offset
Spherical faced
Roller follower

Prof. Sumit S Malusare, FAMT,Ratnagiri

Terminology for cam and follower mechanism
• Cam Profile-: it is the actual working curve of cam, it
is the surface which always remains in contact with
follower.
• Base Circle-: Smallest circle drawn tangent to the
cam profile and concentric with center of rotation of
cam.
• Trace Point-:It is the reference point on follower to
trace cam profile.
• Pressure angle-: It is the angle between the direction
of the follower motion and a normal to the pitch
curve. This angle is very important in designing a
cam profile. If the pressure angle is too large, a
reciprocating follower will jam in its bearings.
• Pitch point-:It is a point on the pitch curve having
the maximum pressure angle.
• Pitch circle-:It is a circle drawn from the centre of the
cam through the pitch points.
Prof. Sumit S Malusare, FAMT,Ratnagiri
Terminology for cam and follower mechanism
• Pitch curve-:It is the curve generated by the
trace point as the follower moves relative to
the cam. For a knife edge follower, the pitch
curve and the cam profile are same
whereas for a roller follower, they are
separated by the radius of the roller.
• Prime circle-: It is the smallest circle that
can be drawn from the center of the cam
and tangent to the pitch curve. For a knife
edge and a flat face follower, the prime
circle and the base circle are identical. For a
roller follower, the prime circle is larger
than the base circle by the radius of the
roller.
• Lift or stroke-: It is the maximum travel of
the follower from its lowest position to the
topmost position.

Prof. Sumit S Malusare, FAMT,Ratnagiri

Influence of pressure angle on cam
• Increase in pressure angle result in
horizontal thrust which results in
jamming of follower in supports
• Increase in vertical component is
desirable.
• Pressure angle is limited my making
surface of cam less convex.
• Size of base circle also controls pressure
angle

Prof. Sumit S Malusare, FAMT,Ratnagiri

Motions of follower

• Simple Harmonic Motion

Prof. Sumit S Malusare, FAMT,Ratnagiri

Motions of follower
• Uniform Velocity

Prof. Sumit S Malusare, FAMT,Ratnagiri

Motions of follower
• Uniform acceleration
and retardation type
of motion

Prof. Sumit S Malusare, FAMT,Ratnagiri

Motions of follower
• Cycloidal Motion

Prof. Sumit S Malusare, FAMT,Ratnagiri

Construction of
Cam Profile for
radial Cam

Prof. Sumit S Malusare, FAMT,Ratnagiri

Numericals on Cam and Follower design
• A rotary disc cam and roller follower has following motion
• Forward stroke of 30 mm in 90 deg cam rotation with SHM
• Dwell of 50° cam rotation
• Return stroke of 30 mm in 120° of cam rotation with SHM
• Remaining is dwell period to complete cycle
• Mass of follower is 1.5 Kg
• Cam shaft speed is 400 rpm
• Pressure angle during forward and return stroke is limited to 25°
• External force during forward stroke is 400N and during return stroke is 80 N
• Determine
• Base circle radius
• Design cam and follower
• Design spring
• Design shaft and other things

Prof. Sumit S Malusare, FAMT,Ratnagiri

Given things in standard notations
• h= 30 mm
• 𝛽𝑖 = 90° = 1.5707 𝑟𝑎𝑑 → SHM
• 𝛽𝑟 = 120° = 2.09439 𝑟𝑎𝑑 → SHM
• Mass of follower 𝑚𝑓 = 1.5 𝐾𝑔
• 𝐹𝑒𝑥𝑡 𝑖 = 400 𝑁 and 𝐹𝑒𝑥𝑡 𝑟 = 80 𝑁
• N= 400 rpm and 𝜔 =41.8879 Rad/Sec
• 𝛼𝑚𝑎𝑥 = 25°

Prof. Sumit S Malusare, FAMT,Ratnagiri

 Determination of Displacement velocity and
acceleration
ℎ 𝜋𝜃
•𝑦= 1
− cos
2 𝛽
ℎ𝜋𝜔 𝜋𝜃
• 𝑦ሶ = Sin
2𝛽 𝛽
ℎ 𝜋𝜔 2 𝜋𝜃
• 𝑦ሷ = cos
2 𝛽 𝛽

Prof. Sumit S Malusare, FAMT,Ratnagiri

Determination of Displacement velocity and
acceleration
Convert Calculator in radian Mode
For forward Stroke
Parameter 𝜃=0 𝛽𝑖 𝛽𝑖 3𝛽𝑖 𝜃 = 𝛽𝑖 Unit
𝜃= 𝜃= 𝜃=
4 2 4
Displacement 0 4.3949 15 25.6066 30 mm
Velocity 0 888.6310 1256.7141 888.6310 0 mm/Sec
Acceleration 105.2886 74.45 0 -74.45 -105.2886 𝑚Τ𝑠𝑒𝑐 2
For Return stroke
Parameter 𝜃=0 𝛽𝑟 𝛽𝑟 3𝛽𝑟 𝜃 = 𝛽𝑟 Unit
𝜃= 𝜃= 𝜃=
4 2 4
Displacement 0 4.3934 15 25.6066 30 mm
Velocity 0 666.4308 942.4755 666.4308 0 mm/Sec
Acceleration 59.2173 41.8729 0 -41.8729 -59.2173 𝑚Τ𝑠𝑒𝑐 2
Convert calculator in Degree Mode
Prof. Sumit S Malusare, FAMT,Ratnagiri
Determination of Base circle radius 𝑹𝒃
• As per PSG 7.113
𝑑𝑦
• tan 𝛼𝑚𝑎𝑥 = 𝑑𝜃
𝑅𝑝 +𝑦𝜃
• Where
• 𝑅𝑝 -: Prime circle radius
𝑑𝑦 𝑉
• =
𝑑𝜃 𝜔
• Assuming maximum pressure angle occurs at 𝜃 = 𝛽𝑖 Τ2 during forward stroke and at 𝜃 =
𝛽𝑟 Τ2 during return stroke
• Calculation for forward stroke
• 𝛼𝑚𝑎𝑥 = 25°
• 𝑉 at 𝜃 = 𝛽𝑖 Τ2 = 1256.7141 m/sec
• 𝑦𝜃 at 𝜃 = 𝛽𝑖 Τ2 = 15 mm
• 𝜔 =41.8879 Rad/Sec
• Hence 𝑅𝑝 during forward stroke = 49.3391 mm

Prof. Sumit S Malusare, FAMT,Ratnagiri

Determination of Base circle radius 𝑹𝒃 …
• Calculation for Return stroke
• 𝛼𝑚𝑎𝑥 = 25°
• 𝑉 at 𝜃 = 𝛽𝑟 Τ2 = 942.4755 m/sec
• 𝑦𝜃 at 𝜃 = 𝛽𝑟 Τ2 = 15 mm
• 𝜔 =41.8879 Rad/Sec
• Hence 𝑅𝑝 during Return stroke = 33.2513 mm
• We will pick up higher value from above calculations
• Let 𝑅𝑝 > 49.3391 mm
• Hence we take 𝑅𝑝 = 60 𝑚𝑚

Prof. Sumit S Malusare, FAMT,Ratnagiri

Determination of Base circle radius 𝑹𝒃 …
• As per standard references
1
𝑅𝑅 = 𝑅 where 𝑅𝑅 is roller radius
5 𝑝
• Hence 𝑅𝑅 = 12 mm
• Also from geometry
• 𝑅𝑝 = 𝑅𝑏 + 𝑅𝑅
• Hence 𝑅𝑏 = 48 𝑚𝑚

Prof. Sumit S Malusare, FAMT,Ratnagiri

Minimum radius of curvature
This formula is applicable for maximum negative acceleration condition

• For forward stroke • For return stroke

• 𝑦𝑚𝑎𝑥=
ሷ -105.2886 𝑚Τ𝑠𝑒𝑐 2 • 𝑦𝑚𝑎𝑥=
ሷ -59.217 𝑚Τ𝑠𝑒𝑐 2
• 𝑦ሶ = 0 𝑚/𝑠𝑒𝑐 • 𝑦ሶ = 0 𝑚/𝑠𝑒𝑐
• 𝑦 = 0.03𝑚 • 𝑦 = 0.03𝑚
• 𝑅𝑝 = 60 𝑚𝑚 • 𝑅𝑝 = 60 𝑚𝑚
• 𝜔 =41.8879 Rad/Sec • 𝜔 =41.8879 Rad/Sec
• Hence • Hence
• 𝜌𝐾𝑚𝑖𝑛 = 0.05399 𝑚 = 53.99 𝑚𝑚 • 𝜌𝐾𝑚𝑖𝑛 = 0.06545𝑚 = 65.45 𝑚𝑚

• Higher value can be taken for further calculations

• 𝜌𝐾𝑚𝑖𝑛 = 0.06545𝑚 = 65.45 𝑚𝑚
• 𝝆𝑪𝒎𝒊𝒏 = 𝝆𝑲𝒎𝒊𝒏 − 𝑹𝒓 = 𝟔𝟓. 𝟒𝟓 − 𝟏𝟐 = 𝟓𝟑. 𝟒𝟓 𝒎𝒎

Prof. Sumit S Malusare, FAMT,Ratnagiri

 Force analysis
For forward stroke
Angle 𝜃 Force due to External Inertia force Spring force 𝐹𝑆𝑝 = Total force
weight of force 𝐹𝑖 = 𝑚 × 𝐷𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 × 𝐾
follower 𝐹𝑊𝑡 N 𝐹𝐸𝑥𝑡 𝐴𝑐𝑐𝑒𝑟𝑒𝑟𝑎𝑡𝑖𝑜𝑛
0 14.715 400 157.9329 0 572.6479
𝛽𝑖
14.715 400 111.675 4.3934K 526.39 + 4.3934K
4
𝛽𝑖
14.715 400 0 15K 414.715 +15K
2
3𝛽𝑖
14.715 400 -111.675 25.6066K 303.04 + 25.6066K
4
𝛽𝑖 14.715 400 -157.9329 30K 256.7821 + 30K
For Return Stroke
0 14.715 80 -88.825 30K 5.89 + 30K
𝛽𝑟
14.715 80 -62.8093 25.6066K 31.9057 + 25.6066K
4
𝛽𝑟
14.715 80 0 15K 94.715 + 15 K
2
3𝛽𝑟
14.715 80 62.8093 4.3934K 157.5243 + 4.3934K
4

𝛽𝑟 14.715 80 88.825
Prof. 0
Sumit S Malusare, FAMT,Ratnagiri 183.54
Force analysis…
𝛽𝑖
• From the table it is vary clear that maximum force occurs at 𝜃 =
2
• 𝐹𝑚𝑎𝑥 = 414.715 +15K
• Now from standard references it is found that “ maximum inertia
force should be smaller than 25% of total force at maximum pressure
angle.
• 0.25 (414.715 +15K) ≥ 𝐹𝑖 𝑚𝑎𝑥𝑖𝑚𝑢𝑚
• 0.25 (414.715 +15K) = 157.9329
• Hence spring stiffness K= 14.4677 N/mm.
• Hence Fmax= 631.7316 N

Prof. Sumit S Malusare, FAMT,Ratnagiri

Force analysis…
• Now this Fmax= 631.7316 N is the
maximum vertical force acting on cam
surface
• Hence normal force acting on cam
𝐹𝑣 631.7316
surface 𝑃𝑛 = =
cos 𝛼𝑚𝑎𝑥 cos 25
• 𝑷𝒏 = 𝟔𝟗𝟕. 𝟎𝟑𝟖𝟔 𝑵

Prof. Sumit S Malusare, FAMT,Ratnagiri

 Design of cam width
• Contact stresses acting on cam surface is
𝑃𝑛 𝐸1 𝐸2 1 1
• 𝜎𝑐 = 0.591 ±
𝑏(𝐸1 + 𝐸2 ) 𝜌𝑐𝑚𝑖𝑛 𝑅𝑟
• Where
• Assuming material for roller is hardened steel and for cam
as Grey cast iron. Hence no sliding 𝜎𝑐 = 4000 𝐾𝑔𝑓 Τ𝑐𝑚2
• 𝑷𝒏 = 𝟔𝟗𝟕. 𝟎𝟑𝟖𝟔 𝑵= 69.7038 Kgf
• 𝐸1 = 1 × 105 𝑁Τ𝑚𝑚2 = 1 × 106 𝐾𝑔𝑓 Τ𝑐𝑚2
• 𝐸2 = 2 × 105 𝑁Τ𝑚𝑚2 = 2 × 106 𝐾𝑔𝑓 Τ𝑐𝑚2
• 𝝆𝑪𝒎𝒊𝒏 = 𝟓𝟑. 𝟒𝟓 𝒎𝒎 = 𝟓. 𝟑𝟒𝟓 𝒄𝒎
• 𝑅𝑟 = 12 𝑚𝑚 = 1.2 𝑐𝑚
• 𝑏 = 1.0351𝑐𝑚 = 10.35 𝑚𝑚 𝑚𝑖𝑛𝑖𝑚𝑢𝑚. ≅ 12 𝑚𝑚
Prof. Sumit S Malusare, FAMT,Ratnagiri
Design of roller Pin
• Selecting material as C30 PSG1.9
• With 𝜎𝑦 = 300 𝑁Τ𝑚𝑚2
• Taking FOS as 3
• Hence 𝜎𝑡 = 100 𝑁Τ𝑚𝑚2
𝜏 = 50 𝑁Τ𝑚𝑚2
• Considering double shear failure at pin
𝑃𝑛
𝜏 = 𝜋
2 𝐷𝑐𝑝 2
4
• 𝑷𝒏 = 𝟔𝟗𝟕. 𝟎𝟑𝟖𝟔 𝑵
Hence
𝐷𝑐𝑝 = 2.9790 ≅ 4 𝑚𝑚

Prof. Sumit S Malusare, FAMT,Ratnagiri

 Spring Design ( PSG 7.100 to PSG 7.108)
• Stiffness required 𝐾 = 14.35 𝑁Τ𝑚𝑚
𝐷
• Assuming spring index 𝐶 = =6
𝑑
• Where D is spring mean diameter and d is wire
diameter
4𝐶−1 0.615
• Wahls stress factor 𝐾𝑠 = + = 1.2525
4𝐶−4 𝐶
• Selecting material for spring as unalloyed cold
drawn steel wire with grade III assuming wire
diameter as 4mm 𝜎𝑢 = 173 𝐾𝑔𝑓Τ𝑚𝑚2
• Now 𝜏 = 0.4𝜎𝑢 for spring steels = 69.2 𝐾𝑔𝑓Τ𝑚𝑚2

Prof. Sumit S Malusare, FAMT,Ratnagiri

Spring Design…
8𝑃𝑛 𝐶
•𝜏= 𝐾𝑠 2
𝜋𝑑
• 𝐾𝑠 = 1.2525
• 𝑷𝒏 = 𝟔𝟗𝟕. 𝟎𝟑𝟖𝟔 𝑵 = 𝟔𝟗. 𝟕𝑲𝒈𝒇
• 𝜏 = 69.2 𝐾𝑔𝑓 Τ𝑚𝑚2 = 6920 𝐾𝑔𝑓 Τ𝑐𝑚2
• 𝑑 = 0.4390 𝑐𝑚 = 4.39 𝑚𝑚 ≅ 5 𝑚𝑚
• Hence 𝐷 = 6 × 𝑑 = 30𝑚𝑚
8𝑃𝑛 𝐶 3 𝑛
• Displacement of spring is 𝑦 =
𝐺𝑑
• 𝐺 = 80 × 103 𝑁Τ𝑚𝑚2
• 𝑦 = 30 mm
• n = 9.96≅ 10 𝑡𝑢𝑟𝑛𝑠
• Considering squaring and grounding n= 12
Prof. Sumit S Malusare, FAMT,Ratnagiri
Spring Design…
• Since maximum displacement allowed is 30 mm
• Pitch of spring = d + 30/10 = 8mm
• Hence length of spring 𝐿𝑓 = 10 × 8 + 2 × 5 = 90 𝑚𝑚

Prof. Sumit S Malusare, FAMT,Ratnagiri

 Stem design
• Distance 𝐴 = 𝐿𝑓 + 𝑅𝑟 + 𝐶𝑙𝑒𝑎𝑟𝑒𝑛𝑐𝑒 + 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒
• 𝐿𝑓 = 90 𝑚𝑚
• 𝑅𝑟 = 12 𝑚𝑚
• Clearance = 5 mm
• 𝐴 = 107 𝑚𝑚
• Now considering buckling failure of stem
• Let radius of stem as 𝑟𝑠 = 𝑅𝑟 Τ3 = 4 𝑚𝑚
• Hence a= 50.2654 𝑚𝑚2
• Selecting material as C30 PSG1.9
• With 𝜎𝑦 = 300 𝑁Τ𝑚𝑚2
• Taking FOS as 3
• Hence 𝜎𝑡 = 100 𝑁Τ𝑚𝑚2
𝜏 = 50 𝑁Τ𝑚𝑚2
• 𝐸 = 2 × 105 𝑁Τ𝑚𝑚2
• n= 1
𝐿
• 𝑟
= 26.75
• 𝑃𝑐 = 13165.54 𝑁 > 𝑷𝒏 = 𝟔𝟗𝟕. 𝟎𝟑𝟖𝟔 𝑵 hence design is safe against
buckling
Prof. Sumit S Malusare, FAMT,Ratnagiri
Design of Cam shaft
• Torque acting on cam shaft is
𝑃𝑛 ×𝑉𝑚𝑎𝑥
• 𝑀𝑡 = PSG 7.116
𝜔
• 𝑷𝒏 = 𝟔𝟗𝟕. 𝟎𝟑𝟖𝟔 𝑵
• 𝑉𝑚𝑎𝑥 = 1256.7141 mm/sec= 1.256 m/sec → from chart
• 𝜔 =41.8879 Rad/Sec
• 𝑀𝑡 = 20.90 𝑁𝑚 = 20900 𝑁𝑚𝑚
• Selecting material as C40 PSG1.9
• With 𝜎𝑦 = 330 𝑁Τ𝑚𝑚2
• Taking FOS as 3
• Hence 𝜎𝑡 = 110 𝑁Τ𝑚𝑚2
• 𝜏 = 55 𝑁Τ𝑚𝑚2
𝜋
• 𝑀𝑡 = 𝐷𝑠 3 𝜏
16
• 𝐷𝑠 = 12.46 mm
• For consideration of jerk motion we consider somewhat higher value
𝐷𝑠 = 20 mm

Prof. Sumit S Malusare, FAMT,Ratnagiri

Design of Cam shaft…
• 𝐷𝑠 = 20 mm
• Hence 𝐷ℎ = 2 × 𝐷 𝑠 = 40𝑚𝑚 < 𝐷𝑏 ℎ𝑒𝑛𝑐𝑒 𝑠𝑒𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑖𝑠 𝑠𝑎𝑓𝑒
• Length of hub 𝐿ℎ = 40 𝑚𝑚
• Key selection
For shaft diameter as 20 mm we select 6 × 6 𝑘𝑒𝑦 PSG 5.16

Prof. Sumit S Malusare, FAMT,Ratnagiri

Determination of thickness of Guide (B)
• From PSG 7.116
𝐵
• 𝛼𝑚𝑎𝑥 = tan−1
𝜇 2𝐴+𝐵
• 𝛼𝑚𝑎𝑥 = 25°
• A= 107 mm
• 𝜇 = 0.3 𝑎𝑠𝑠𝑢𝑚𝑒𝑑
• Hence B= 34.79 mm

Prof. Sumit S Malusare, FAMT,Ratnagiri

Final Assembly

Prof. Sumit S Malusare, FAMT,Ratnagiri

Thank You..
Prof Sumit Suresh Malusare
Assistant Professor
Mechanical Engineering Department
Finolex Academy of Management and Technology, Ratnagiri
sumitsmalusare@gmail.com
sumit.malusare@famt.ac.in
9403098168

Prof Sumit S Malusare,FAMT,Ratnagiri