Design of Cam Profile

Jiting Li, Mileta M. Tomovic School of Technology Mechanical Engineering Technology

Outline
Task Basic Principle Graphical Layout of Cam Profiles Analytical Design of Cam Profiles Simulation

Task
The task is to determine the exact shape of a cam surface required to deliver a specified follower motion. We assume here that the required motion has been completely determined------ graphically as well as analytically. We will only address the case of plate cams.

Basic Principle
In constructing the cam profile, we employ the principle of kinematic inversion, imagining the cam to be stationary and allowing the follower to rotate opposite to the direction of cam rotation. Taking the cams with knife-edge follower for example, the locus generated by the trace point as the follower moves relative to the cam is identical to cam surface. By this way cam surface can be figured out.

inversion

Graphical Layout of Cam Profiles

For the case of reciprocating knife-edge follower
As shown in left figure, the displacement diagram of the follower is given, s=s (). Construct the plate cam profile.

Graphical Layout of Cam Profiles

For the case of reciprocating knife-edge follower
Step1: divide the displacement-diagram abscissa into a number of segments.

Step2: divide the prime circle into corresponding segments. Step3: transfer distances, by means of dividers, from the displacement diagram directly onto the cam layout to locate the corresponding positions of the trace point.

Graphical Layout of Cam Profiles

For the case of reciprocating knife-edge follower

Step4: draw a smooth curve through these points. The curve is just the required cam profile.

Graphical Layout of Cam Profiles

For the case of reciprocating offset roller follower
As shown in left figure, the displacement diagram of the follower is given, s=s (). Construct the plate cam profile.

Graphical Layout of Cam Profiles

For the case of reciprocating offset roller follower

Step1: construct the prime circle with radius r0. Step2: construct the offset circle with radius equal to the amount of offset e.

Graphical Layout of Cam Profiles

For the case of reciprocating offset roller follower
Step3: divide the displacement-diagram abscissa into a number of segments. Step4: divide the offset circle into corresponding segments and assign station numbers to the boundaries of these segments.

Step5: construct lines tangent to the offset circle from these station, dividing the prime circle into corresponding segments.

Graphical Layout of Cam Profiles

For the case of reciprocating offset roller follower

Step6: transfer distances, by means of dividers, from the displacement diagram directly onto the cam layout to locate the corresponding positions of the trace point, always measuring outward from the prime circle.

Graphical Layout of Cam Profiles

For the case of reciprocating offset roller follower

Step7: draw a smooth curve through these points. The curve is just the required cam profile.

Step8: draw the roller in its proper position at each station and then construct the cam profile as a smooth curve tangent to all these roller positions.

Graphical Layout of Cam Profiles

For the case of reciprocating flat-face follower
As shown in left figure, the displacement diagram of the follower is given, s=s (). Construct the plate cam profile.

Graphical Layout of Cam Profiles

For the case of reciprocating flat-face follower
Step1: divide the displacement-diagram abscissa into a number of segments. Step2: divide the prime circle into corresponding segments. Step3: transfer distances from the displacement diagram directly onto the cam layout. Step4: construct a line representing the flat face of the follower in each position.

Graphical Layout of Cam Profiles

For the case of reciprocating flat-face follower

Step5: construct a smooth curve tangent to all the follower positions. This curve is the required cam profile.

Graphical Layout of Cam Profiles

For the case of oscillating follower
As shown in left figure, the displacement diagram of the follower, radius of prime circle, and follower length are given. Construct the plate cam profile.

Graphical Layout of Cam Profiles

For the case of reciprocating flat-face follower
Step1: divide the displacement-diagram abscissa into a number of segments. Step2: draw a circle about camshaft center O with radius OA0. Step3: divide the circle and give the station numbers to correspond to the displacement diagram.

Graphical Layout of Cam Profiles

For the case of reciprocating flat-face follower
Step4: draw arcs about each of these centers, all with equal radii corresponding to the length of follower. NOTE: in the case of an oscillating follower, the ordinate values of the displacement diagram represent angular movements of the follower. Step5: calculate the angular displacement at each station traveled by the follower. Step6: measure outward along the arc from the prime circle to locate the trace point at each station.

Graphical Layout of Cam Profiles

For the case of reciprocating flat-face follower

Step7: construct a smooth curve through these points. The curve is just the required cam profile.

Analytical Design of Cam Profiles

For the case of reciprocating offset roller follower
As shown in left figure, the displacement diagram of the follower is given, s=s (). The offset distance e, radius of prime circle r0, and radius of roller rr are also known. Formulate the equation of plate cam profile.

Analytical Design of Cam Profiles

For the case of reciprocating offset roller follower
Step1: Equation of pitch curve

1) draw prime circle, offset circle, and the initial position of the follower. 2) define the Cartesian coordinate system O-xy. 3) rotate the follower backward an arbitrary angle around the camshaft center O.

Analytical Design of Cam Profiles

For the case of reciprocating offset roller follower
4) determine the coordinates (x,y) of trace point B.
x = ( s0 + s) sin + e cos y = ( s0 + s ) cos e sin
(1)

where

s0 = r02 e 2
s is the displacement of the follower when cam rotates angle .

Analytical Design of Cam Profiles

For the case of reciprocating offset roller follower
Step2: Equation of cam profile
We know that the point B on the cam profile corresponding to the trace point B must lie on its normal n-n. The slope at point B is
dx dx d tg = = dy dy d

where dx/d and dy/d can be calculated from Eq. (1).

Analytical Design of Cam Profiles

For the case of reciprocating offset roller follower
Therefore the coordinates of point B is
x ' = x m rr cos y ' = y m rr sin

Analytical Design of Cam Profiles

For the case of reciprocating flat-face follower

The method is similar with that of design the cam profile with roller follower.

Analytical Design of Cam Profiles

For the case of reciprocating flat-face follower

Step1: draw prime circle and the initial position of the follower. Step2: define the Cartesian coordinate system O-xy. Step3: rotate the follower backward an arbitrary angle around the camshaft center O.

Analytical Design of Cam Profiles

For the case of reciprocating flat-face follower

Step4: determine the coordinates (x,y) of point B.

x = BP sin + OP cos = (r0 + s ) sin +

ds cos d ds y = BP cos OP sin = (r0 + s ) cos sin d

Analytical Design of Cam Profiles

For the case of oscillating roller follower

The method is similar with that of design the cam profile with reciprocating roller follower.

Analytical Design of Cam Profiles

For the case of oscillating roller follower
Step1: Equation of pitch curve
1) draw prime circle and the initial position of the follower. 2) define the Cartesian coordinate system O-xy. 3) rotate A0 backward an arbitrary angle around the camshaft center O. 4) Locate the follower according to its angular displacement.

Analytical Design of Cam Profiles

For the case of oscillating roller follower
5) determine the coordinates (x,y) of trace point B.
x = OA sin ABsin( + 0 + ) y = OA cos ABcos( + 0 + )

ie.
x = a sin l sin( + 0 + ) y = a cos l cos( + 0 + )

Step2: Equation of cam profile

The method is same as that of design the cam profile with reciprocating roller follower.

Simulation
The synthesis results can be validated by simulation. Here is an example. The simulation is done with software ADAMS/VIEW. Example: design a plate cam profile, as shown in below.
Knowing: the cam rotates with constant angular velocity in clockwise. The radius of prime circle r0=30mm. The knife-edge follower rises with uniform motion, and the lift is 50mm during which the cam rotates 180. Then the follower dwells during which the cam rotates 60. With cam rotating 120 to complete the work cycle, the follower returns to its initial position with parabolic motion.

Simulation
The design result is shown as following table which gives the coordinates of points on the cam profile.
Cam rotating angle ()
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

x (mm)
0.00 5.69 12.16 19.16 26.42 33.62 40.41 46.46 51.42 55.00 56.90 56.90 54.84 50.64 44.28 35.83 25.46 13.4

y (mm)
30.00 32.27 33.41 33.19 31.49 28.21 23.33 16.91 9.06 0.00 -10.03 -20.71 -31.66 -42.49 -52.77 -62.06 -69.95 -76.04

Cam rotating angle()

180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350

x (mm)
0.00 -13.89 -27.36 -40.00 -51.42 -61.28 -69.28 -74.52 -76.04 -73.75 -67.84 -58.86 -47.63 -36.28 -26.42 -18.12 -11.21 -5.33

y (mm)
-80.00 -78.78 -75.17 -69.28 -61.28 -51.42 -40.00 -27.12 -13.40 0.00 11.96 21.42 27.50 30.44 31.49 31.39 30.80 30.22

Simulation
Simulation result

Follower displacement: Virtual Prototype Solid red line ---- actual displacement Dash blue line---- given displacement

Simulation

Simulation shows that the error between the actual follower displacement and given follower displacement varies, but the maximum absolute error is 0.3747mm. The error is brought by step length of programming and simulation and is acceptable. Therefore the synthesis result is proved to be correct.

Reference
1. Wu Ruixiang et al.,Theory of Machines and Mechanisms. Beihang University, 2005. 2. Joseph Edward Shigley and John Joseph Uicker, Jr., Theory of Machines and Mechanisms, second edition. McGraw-Hill, Inc., 1995.

Acknowledgments
The author wishes to acknowledge the support from the Society for Manufacturing Engineers - Education Foundation, SME-EF Grant #5004 for Curriculum Modules in Product Lifecycle Management.