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heat-treated (austempered), 255 300 BHN, phosphate-coated Gray-iron, class 30, oil-quenched, 270 415 BHN Gray-iron, class 35, 225 255 BHN Gray-iron, class 45, 220 240 BHN Nodular-iron, Grade 80-60-03, 270 241 BHN Nodular-iron, Grade 100-70-03, heat-treated, 240 260 BHN High-strength yellow brass, drawn, 157 162 BHN Nickel bronze, 80 90 BHN SAE 65 phosphor-bronze sand casting, 65 75 BHN SAE 660 continuous-cast bronze, 75 80 BHN Aluminum bronze Zinc die casting, 70 BHN Random- ber cotton-base phenolic Graphitized laminated phenolic Nema Grade L laminated phenolic Linen-base laminated phenolic Acetal resin Polyurethane rubber Polycarbonate resin High-molecular-weight polyethylene
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velocity of 600 ft/min Table 93 also includes static hertzian stress values, which are presented for information and comparison only and do not relate to the fatigue tests In plotting K versus life, a least-square curve tting line is drawn through the normal scatter of signi cant points obtained from tests The equation for the K factor as a function of life is derived from the slope of these tting lines log10 K = B - log10 N A (915)
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where constants A and B are given in Table 93 and N is the number of stress cycles for which a K value is required For numbers other than 100 million cycles the load stress factors can be interpreted from the load-life curves similar to Fig 99 Figure 99 presents typical load-life test data obtained from the roll test machine Comparisons are given for pure rolling and up to 300 percent sliding to indicate trends and slope comparison of the materials Figure 99a shows nodular iron and class 45 cast iron and Fig 99b shows cast bronze Let us consider the design approach for choosing the optimum combination of materials In fatigue design criteria, this choice is a modi cation of Fail-Safe Design by Fuchs and Stephens (1980) Fail-safe design recognizes that fatigue cracks may occur and arranges the structure so that cracks will not lead to a failure before they are detected In cam-follower system design we design and operate the machine so that the roller follower will wear out before the cam is ever affected In this manner the rollers will be periodically replaced This is the easiest and least expensive solution to the fatigue problem Therefore the roller diameter should be measured periodically and replaced when it has shown a reduction in size but before destructive wear of either the roller or cam occurs Experience over time will be necessary to succeed with this approach to discover compatible materials for each particular machine It is suggested that dependent on the size and reliability of the system a reduction of the roller diameter from -00004 to -0002 in requires a replacement For example, the author designed a newspaper folding mechanism run at 70,000 papers per hour with commercial ball-bearing rollers SAE 52100 hardened RC60-62 They were measured every six months and if the diameters were reduced by -0001 in they were replaced The cam material is SAE 8620 air-hardened die steel RC 58-60 and still running with accuracy and some surface polish over 35 years as well as operating properly and at a minimum cost Next, let us discuss some of the test data in Table 93 in which it was stated that the rollers were of equal size and the softer material of the combination failed rst However, this is not the case with cam-follower machines which use a roller smaller than the cam by a ratio of between 1 and 6 or 1 and 10 depending on the design Accordingly the follower roller surface has more fatigue stress cycles than the cam surface and will tend to fail rst This fact slants the test data of Table 93 positively to the periodic replacement of the roller follower Also, it may be noted that the roller will wear out rst even though it is a harder and more expensive surface material than that of the cam Occasionally, a soft metal ring may be added to the commercial roller follower as a choice over the manufactured bearing surface A shortcoming is the larger rotational moment of inertia of the roller and more skidding produced in contact with the cam
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