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INTRODUCTION
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FIGURE 126
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Cam nomenclature
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Suppose that, as in Figure 127a, the cam had a pressure angle of approximately 60 degrees It can be seen that there is a strong possibility that clockwise rotation of the cam would not cause the translating follower to rise, but to jam against the guides and cause bending in the follower stem Designers often empirically limit the pressure angle to 30 degrees or less for smooth cam-follower action However, if the follower bearings are strong, the cam-follower is rigid, and the cam-follower overhang is small, the maximum pressure angle may be increased to more than 30 degrees In at-faced followers, this locking action does not exist In Fig 127b, we see a follower face normal to the translating follower motion in which the pressure angle is constant at zero degrees and thus no jamming occurs Let us establish the following: a = pressure angle and am = maximum pressure angle The pitch point (see Fig 126) is the point on the cam pitch having the maximum pressure angle, am The pitch circle (see Fig 126) is one with its center at the cam axis passing through the pitch point The radius of the pitch circle is Rp The radius of curvature at any point on the pitch curve is the radius of curvature of the curve at that point Here, we de ne the curvature as a measure of the rate of change of the angle of inclination of the tangent with respect to the arc length The transition point or crossover point is the position of maximum velocity where the acceleration changes from positive to negative and the inertia force of the follower changes direction accordingly
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CAM DESIGN HANDBOOK
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(a) Roller follower (60 deg pressure angle)
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FIGURE 127 Signi cance of pressure angle
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(b) Flat-faced follower (zero pressure angle)
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18 OTHER METHODS THAN CAMS
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Other methods than cams may employ mechanical, electrical, or uid devices individually or in combination to satisfy the design requirements Cam-follower systems and other methods have speci c functional applications where they are selectively applied The following are some of the major systems utilized and their performance compared to camfollower systems: (a) linkage mechanisms; (b) servo valve-controlled hydraulic cylinder; (c) stepper motor and controller, and (d) industrial adjustable mechanism The linkage mechanism may be of either four-bar or multiple-bar construction depending on the complexity of the designed motion These mechanisms cannot produce exact dwell action (only an approximation), with poor force transmission and high torque existing in the cyclical action A servo valve-controlled hydraulic cylinder yields equivalent performance to camfollower systems for high force level requirements This machinery has limited control and speed application The servo motor (stepping motor), programmable servo controller (stepper controller), and ball-screw combination is another replacement for cams Motion controls can be changed easily This mechanism has the advantage of programmability in small force and low power applications but has speed limitations The last alternate method involves the use of adjustable mechanisms in industrial applications To achieve exibility, the cams are replaced by multi-degree-of-freedom systems with multi-actuators and logic controllers The adjustable or programmable mechanisms are utilized in exible xturing and exible assembly systems Their design is often complicated and costly In general these devices are easier to manufacture but have limited speeds and limited force levels and are more costly Cam-follower systems in comparison are complex in construction, are smaller, have better dynamic properties, carry a heavier load, and transmit more power over a longer time period The applications are high-speed automobile valve controls, indexing tables, and industrial machinery such as paper converting and textile machinery Designing cams and forecasting their performance is easy
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INTRODUCTION
19 DESIGN CONSIDERATIONS
This section is a collection of introductory thoughts relating to the proper design and performance of cam-follower systems Cam-follower systems have been built in an extreme range of sizes, from small mechanisms that have been produced in microelectromechanical systems (MEMS), in which forty of them could t in the period at the end of this sentence, to the largest machine being a four-story high newspaper printing and folding press (heavy mass-moving parts) handling seventy thousand complete newspapers per hour In between these extremes is a small high-speed punching mechanism running at 12,000 rpm, with some dynamic loading and elasticity Figure 128 shows a high-production cam-operated press for sheet metal drawn parts (eyelets) for the cosmetic industry This machine has multiple cam followers for each stage of operation and runs at 70 rpm The following is a brief list of ideas to guide the engineer-designer in creating camfollower machinery The rst step in designing a cam system is to establish the proposed design speed of the complete machine This decision is a critical one and should be based on the best experience and judgment available The customer should be helpful in this decision After the design speed is determined, establish a time chart to synchronize the cam system with other actions of the machine Positive drive, closed-track radial cams or conjugate dual cams with roller followers are the most popular choices The cam contour should be smooth with no abrupt changes in its curvature Note that curvature at any point on a cam is directly related to acceleration of the follower The minimum curvature or sharpness of a convex cam contour is dependent on the value of the maximum negative acceleration of the follower That is, the larger the negative acceleration, the sharper the cam surface will be The cam size should be as small as possible to minimize the cam-follower sliding velocity, surface wear, torque on the camshaft, and cost and space requirements The pressure angle should be kept to a minimum; 30 degrees is a general arbitrary limit for all followers Proper dynamic cam-follower design necessitates the study of the cam-follower acceleration curve The maximum follower acceleration should be as low as possible to keep the inertia forces and stresses small The noise, surface wear, and vibration of a cam-follower system are dependent on the shape of the follower acceleration curve; hence, smoothness and continuity of the acceleration curve are essential The moving parts of the cam-follower mechanism should be lightweight and as rigid as possible to keep the inertia forces, noise, and wear at a minimum, especially at high speeds The torque curve should be investigated in addition to the force distribution of the system Manufacturing methods and accuracy of cam cutting and inspection are of paramount importance in ensuring the anticipated performance of a system Small surface errors that are imperceptible to the eye may produce high stress and vibrations in the follower linkages