Complex Engineering Problem
Complex Engineering Problem
Page | 1
Analysis of Cam and Follower Mechanisms
Cam and follower mechanisms are ingenious devices for converting rotary motion into linear
or reciprocating motion. The cam, a shaped disc or plate, rotates and its profile dictates the
movement of the follower, which can be a rod or lever. By designing the cam's shape precisely,
engineers can achieve complex and specific motions for the follower. This allows for great
control and opens up a wide range of applications in machines and automation systems.
Cams: Cams are used to convert rotary into reciprocating motion.
Follower: Follower is a component that is in direct contact with the cam and translates
the rotary motion of the cam into linear or reciprocating motion.
Types of Cams and Follower Motion:
Uniform Velocity.
Simple Harmonic Motion (S.H.M).
Uniform Acceleration and Retardation.
Cycloidal Motion.
Uniform Velocity:
We will discuss about the displacement, velocity and acceleration diagrams when the
follower moves with uniform velocity:
In the drawn below diagram the base (abscissa) represents the time or it may represent the
angular displacement of the Cam in degree. The vertical axis or ordinate represents the
displacement, velocity or acceleration of the follower. Although the follower moves with
uniform velocity during its rise and return stroke the slope of the displacement curves must
be constant. Now the follower remains at rest during part of the Cam rotation. The periods
during which the follower remains at rest are known as dwell periods. In the above diagram
we see that acceleration or retardation of the follower at the beginning and at the end of
each stroke is infinite. This is due to that the follower is required to start from rest and has
to gain a velocity within no time. This is only possible when the acceleration or retardation
at the beginning and at the end of each stroke is infinite.
Page | 2
Figure 1: Follower motion with Uniform velocity
Formula:
Formula for the max. uniform velocity’s for Rise and Return of the cam is given by:
𝒅𝒔
V=
𝒅𝒕
𝒅𝒔 𝒅𝜽
V= x
𝒅𝒕 𝒅𝜽
As,
𝒅𝜽
=𝝎
𝒅𝒕
So,
𝒅𝒔
V=𝝎
𝒅𝜽
Page | 3
Parameters:
S = Stroke of the follower.
𝜃 = Angular displacement of the cam during out stroke (Rise).
𝜃 = Angular displacement of the cam during return stroke (Return).
𝜃 = Angular displacement of the cam during Dwell period.
𝜔 = Angular Velocity of the cam.
Example:
A Cam is to give the following motion to a knife-edged follower:
1. Outstroke during 60° of Cam rotation.
2. Dwell for the next 30° of Cam rotation.
3. Return stroke during next 60° of Cam rotation.
4. Dwell for the remaining 210° of Cam rotation.
The stroke of the follower is 40mm and the minimum radius of the Cam is 50mm. The follower
moves with uniform velocity during both the outstroke and return stroke. Draw the profile of
the Cam when:
The axis of the follower passes through the axis of the Cam shaft.
Construction: First of all we will draw the displacement diagram.
Page | 4
Profile of the Cam when the axis of follower passes through the axis of Cam shaft.
Page | 5
Simple Harmonic Motion (S.H.M):
Consider a particle is moving clockwise in an orbit of a circle from point A to B. Lets
create a projection line of the particle at the center of the circle when particle is at different
positions, after that these projections line makes a vertical line from point A to B.
Showing that when particle moves in a circle it cause a up and down motion (To and Fro)
which is also called a Simple Harmonic Motion.
If a distance from point A and B is consider as the Stroke (S) of the cam which is equal to the
diameter of the circle (d) than the displacement (y) covered by a particle is given by:
O S
S/2 𝜽 S/2cos𝜽
S/2sin𝜽 S/2
P
y
Mathematically:
B
y = OB – OP 𝒅 𝒔 S S
− cos𝜃 = ( sin𝜃)
𝒅𝜽 𝟐 2 2
y = S/2 – S/2cos𝜽
)
As,
𝒅𝒚
V=𝝎
𝒅𝜽
a = 𝝎 (𝝎 S/2cos𝜽)
Page | 6
a = 𝝎𝟐 (S/2cos𝜽) Used for making cos curve for acceleration.
𝑪𝒐𝒔𝒊𝒏𝒆 𝒘𝒂𝒗𝒆
a
We will discuss about the displacement, velocity and acceleration diagram when
follower moves with simple harmonic motion:
In a cam and follower mechanism with SHM, the displacement curve plotted against cam
angle (or time) will be a cosine wave. This is because the follower's position varies
smoothly back and forth according to the cosine function. While the follower moves with
constant speed during its upward and downward strokes (represented by the constant
slope of the displacement curve), there may be periods where it remains stationary (dwell
periods).
It's important to note that SHM doesn't involve instantaneous changes in speed. In reality,
the follower's acceleration (rate of speed change) cannot be infinite at the beginning and
end of each stroke. To achieve smooth, predictable motion, the cam profile is designed
to gradually increase and decrease the follower's speed during these transition periods.
This avoids abrupt changes and ensures the follower transitions smoothly between rest
and motion.
Page | 7
Figure 2: Motion of a follower with Simple Harmonic Motion
Page | 8
Now,
The velocity of cam during out stroke is given by:
𝝅𝒔 𝟏
Vp = 𝒙
𝟐 𝒕𝒐
𝝅𝒔 𝝎
Vp = ∗ max. out stoke velocity
𝟐 𝜽𝒐
𝝅𝟐 𝝎𝟐 𝑺
ap = max. out stoke acceleration
𝟐(𝜽𝟐𝒐 )
Similarly,
𝝅𝒔 𝝎
VR = ∗ max. Return stoke velocity
𝟐 𝜽𝑹
𝝅𝟐 𝝎𝟐 𝑺
aR = max. Return stoke acceleration
𝟐(𝜽𝟐𝑹 )
Parameters:
S = Stroke of the follower.
𝜃 = Angular displacement of the cam during out stroke (Rise).
𝜃 = Angular displacement of the cam during return stroke (Return).
𝜃 = Angular displacement of the cam during Dwell period.
𝜔 = Angular Velocity of the cam.
𝑡 = Time required for the follower during out stroke.
𝑡 = Time required for the follower during return stroke.
Example:
A cam with a minimum radius of (rc =25 mm) is to be designed for a knife-edge follower with
the following data:
To raise the follower through 35 mm during 60° rotation of the cam
Dwell for next 40° of the cam rotation
Descending of the follower during the next 90° fo the cam rotation
Dwell during the rest of the cam rotation.
Draw the profile of the cam if the ascending and descending of the cam is with simple harmonic
motion and the line of stroke of the follower is offset x=10 mm from the axis of the cam shaft.
What is the maximum velocity and acceleration of the follower during the ascent and the
descent if the cam rotates at 150 rpm
Page | 9
Sol:
S = 35 mm; 𝜃 = 60°
N = 150 rpm 𝜃 = 40°
rc = 25 mm 𝜃 = 90°
x = 10 mm
a. Draw the displacement diagram of the follower:
Page | 10
During Rise:
As,
2𝜋 ∗ 𝑁
𝜔=
60
2𝜋 ∗ 150
𝜔=
60
𝝎 = 𝟏𝟓. 𝟕𝟏 𝒓𝒂𝒅/𝒔
Now,
Vmax = ∗
.
Vmax = ∗
( )
amax =
( )
( . ) ( )
amax =
( ∗ / )
VR = 𝟓𝟒𝟗. 𝟖 𝒎𝒎/𝒔
And,
aR =
( )
( , ) ( )
aR =
( ∗ / )
aR = 17276 mm/s2
aR = 17.276 m/s2
Page | 11
Uses:
Uses of Simple Harmonic Motion type cam and Follower:
1. Engine Valve Actuation: cars, motorcycles, lawnmowers, generators.
2. High-Speed Machinery: Pick and place robots, Printing presses, Textile looms.
3. Vibration Isolation Systems: HVAC systems, Appliance manufacturing (Washing
machines, dryers).
4. Medical Devices: Insulin pumps, Blood analysis equipment, Dialysis machines.
Page | 12
Uniform Acceleration and Retardation:
Cam and follower mechanisms with uniform acceleration and retardation profiles offer a
balance between smooth motion and efficient use of cam rotation. Unlike SHM, which
focuses on controlled transitions throughout the cycle, these cams prioritize constant
acceleration and deceleration during the follower's rise and fall. This translates to a
ramped displacement curve on the diagram, with a constant slope during these active
portions. Dwell periods, where the follower remains at rest, are also present.
While the concept suggests the follower reaches its target speed instantaneously at the
beginning and end of strokes, this is not physically possible. The cam profile is designed
to achieve these transitions smoothly through finite acceleration and deceleration
periods. This avoids the wear and tear associated with abrupt changes in speed and ensures
a more predictable follower motion. This type of cam finds applications where controlled
movement with efficient use of cam rotation is desired.
Page | 13
Construction of the Diagram:
a. Divide the Cam diameter during outstroke (0 ) in the any even number, of equal parts
(say eight) and draw vertical lines through these points.
b. Divide the stroke of the follower(s) in to the same number of equal even parts.
c. Join Aa to intersect the vertical line through point 1 at B. Similarly, obtain the other
point as usual.
Formula: 𝒕𝒐 𝜽𝒐
𝟐 𝟐
As,
𝜽𝒐
to = ⇒ time for out stroke.
𝝎
𝜽𝑹
tR = ⇒ time for Return stroke
𝝎
The mean velocity during out stroke is the point at which velocity is increased uniformly is
given by,
𝒔
Vo,mean =
𝒕𝒐
Now,
The max. out stroke velocity is,
𝒔
Vo,max = 𝒕𝒐
𝟐
𝟐𝒔
Vo,max = 𝜽𝒐
𝝎
𝟐𝒔𝝎
Vo,max =
𝜽𝒐
And,
The max. out stroke acceleration is,
𝑽𝒐
ao,max = 𝒕𝒐
𝟐
𝟐𝑽𝒐
ao,max =
𝒕𝒐
𝟐𝒔𝝎
𝟐( )
𝜽𝒐
ao,max = 𝜽𝒐
𝝎
𝟒𝝎𝟐 𝑺
ao,max =
(𝜽𝟎 )𝟐
Page | 14
Similarly,
For Return Stroke,
𝒔
VR,mean =
𝒕𝑹
𝟐𝒔𝝎
VR,max =
𝜽𝑹
𝟒𝝎𝟐 𝑺
aR,max =
(𝜽𝑹 )𝟐
Parameters:
S = Stroke of the follower.
𝜃 = Angular displacement of the cam during out stroke (Rise).
𝜃 = Angular displacement of the cam during return stroke (Return).
𝜃 = Angular displacement of the cam during Dwell period.
𝜔 = Angular Velocity of the cam.
𝑡 = Time required for the follower during out stroke.
𝑡 = Time required for the follower during return stroke.
Examples:
A cam rotating clockwise at a uniform speed of 1000 r.p.m. is required to give a roller follower
the motion defined below:
1. Follower to move outwards though 50mm during 120° of cam rotation,
2. Follower to dwell for next 60° of cam rotation,
3. Follower to return to its starting position during next 90° of cam rotation,
4. Follower to dwell for the rest of the cam rotation.
The minimum radius of the cam is 50 mm and the diameter of roller is 10 mm. The line of
stroke of the follower is off-set by 20 mm from the axis of the cam shaft. If the displacement
of the follower takes place with uniform and equal acceleration and retardation on both the
outward and return strokes, draw profile of the cam and find the maximum velocity and
acceleration during out stroke and return stroke.
Sol:
N = 1000 r.p.m.;
S = 50 mm = 0.05 m;
O = 120° = 2 /3 rad = 2.1 rad;
R = 90° = /2 rad = 1.571 rad
Since the displacement of the follower takes place with uniform and equal acceleration and
retardation on both outward and return strokes, therefore the displacement diagram, as shown
in figure, is drawn in the similar manner as discussed in the previous example. But in this case,
the angular displacement and stroke of the follower is divided into eight equal parts.
Page | 15
Now, the profile of the cam, as shown in below figure, is drawn as discussed in the following
steps:
1. Draw a base circle with center O and radius equal to the minimum radius of the cam
(i.e., 50 mm).
2. Draw a prime circle with centre O and radius OA = Minimum radius of the cam + radius
of roller = 50 + 5 = 55 mm
3. Draw a off-set circle with centre O and radius equal to 20 mm.
4. Divide the angular displacements of the can during out stroke and return stroke into
eight equal parts as shown by points 0, 1, 2, ...... and 0, 1, 2, ...... etc. on the prime
circle in figure.
5. From these points draw tangents to the off-set circle.
6. Set off 1B, 2C, 3D .... etc. equal to the displacements as measured from the
displacement diagram.
7. By joining the points A, B, C .... T, U, A with a smooth curve, we get a pitch curve.
8. Now from points A, B, C ...... T, U, draw circles with radius equal to the radius of the
roller.
9. Join the bottoms of these circles with a smooth curve to obtain the profile of the cam as
shown in figure.
Vo,max =
( . )( . )
Vo,max =
.
Vo,max = 𝟓 𝒎/𝒔
And,
ao,max =
( )
( . ) ( . )
ao,max =
( . )
VR,max =
( . )( . )
VR,max =
.
VR,max = 𝟔. 𝟔𝟔 m/s
And,
aR,max =
( )
( . ) ( . )
aR,max =
( . )
Page | 17
Uses:
Uses of uniform acceleration and retardation type cam and follower:
1. Conveyor belts.
2. Sorting machines.
3. Carton erecting machines.
4. Blister pack machines.
5. Slicing machines.
6. Dough feeding mechanisms.
Page | 18
Cycloidal Motion:
Cycloidal cam and follower mechanisms offer a unique approach to follower motion,
prioritizing smooth transitions and minimal wear. Unlike uniform acceleration and
retardation (UAR) profiles, which focus on constant acceleration/deceleration during
specific periods, cycloidal cams aim for the smoothest possible follower movement
throughout the entire cycle.
The cam profile is designed based on the mathematical concept of a cycloid; a curve traced
by a point on a rolling circle. This results in a distinctive displacement curve on the
diagram, with continuous changes in slope throughout the follower's rise and fall. Dwell
periods, where the follower remains stationary, can also be incorporated.
And,
S = 2𝝅𝒓
Page | 19
Construction of Diagram:
a. Draw a horizontal line representing the follower's baseline position (usually its mid-
stroke position)
b. Mark a point on this line representing the starting point of the follower's displacement
(either top or bottom depending on the direction of movement)
c. Imagine a circle with a diameter equal to the follower's total rise or fall (displacement).
This circle is often referred to as the generating circle.
d. Draw a point (tracing point) on the circumference of this circle.
e. Divide the circumference of the generating circle into a specific number of equal parts
(typically even numbers for smooth representation).
f. Mark these division points on the circle's circumference.
g. For each division point on the generating circle, pause the imaginary rolling motion and
project the position of the tracing point vertically down to the baseline.
h. This creates corresponding points on the baseline that represent the follower's
displacement at different positions of the rolling circle.
i. Join the projected points on the baseline with a smooth curve. This curve represents the
follower's displacement throughout the cycle.
Formula:
Displacement of the follower ather time “t” seconds:
x = OA – OB
x = r𝜃 – r𝑠𝑖𝑛𝜃
x = r(𝜃 – 𝑠𝑖𝑛𝜃)
𝜃
x = r[2𝜋 – sin (2𝜋 )]
𝜃𝑜
𝜃
x= [2𝜋 – sin (2𝜋 )] 1 rev ⟹ 𝜽=2𝝅
𝜃𝑜
Now,
Velocity of the follower ather time “t” seconds:
V= 𝑑𝑡
V = 𝑑𝑡 𝑆 [ – 2𝜋 sin (2𝜋 )]
Page | 20
For max. Velocity
V=
𝜃𝑜
𝜔 [1 – cos (2𝜋 )]
𝜃
𝜃𝑜
1 𝐜𝐨𝐬 (𝟐𝝅 ) = -1
𝜽
𝜽𝒐
𝜽𝒐
V= 𝜔 [1 – cos (𝜋)] 𝜽= put in eqn. 1
𝜃𝑜 𝟐
V= 𝜔 [1 – (−1)]
𝜃𝑜
V= 𝜔 [2]
𝜃𝑜
𝜔
𝑉 = Max. Velocity During out Stroke.
𝜃𝑜
And,
Acceleration of the follower ather time “t” seconds:
a=
𝜔 𝜃
a= [1 – cos (2𝜋 )]
𝜃𝑜 𝜃𝑜
𝜔
a= [ sin 𝜔]
𝜃𝑜
2𝜋 𝜔2 2𝜋 𝜃𝑜 so,
a= [sin ]
(𝜃 ) 𝜃𝑜 4 𝝅
𝜽
consider 𝟐𝝅 𝜽 =
2𝜋 𝜔2 𝜋 𝒐 𝟐
a= [sin ] 𝜽𝒐
(𝜃 ) 2
𝜽= 𝟒
put in eqn. 2
2𝜋 𝜔2
a= [1]
(𝜃 )
2𝜋 𝜔2
ao= Max. Acceleration During out Stroke.
(𝜃 )
Similarly,
𝜔
𝑉 = Max. Velocity During ReturnStroke.
𝜃𝑅
2𝜋 𝜔2
aR= Max. Acceleration During Return Stroke.
(𝜃 )
Page | 21
Parameters:
S = Stroke of the follower.
𝜃 = Angular displacement of the cam during out stroke (Rise).
𝜃 = Angular displacement of the cam during return stroke (Return).
𝜃 = Angular displacement of the cam during Dwell period.
𝜔 = Angular Velocity of the cam.
Example:
Draw the CAM PROFILE when the ROLLER FOLLOWER moves with CYCLOIDAL
MOTION during out stroke and return stroke, as given below :
1. Out stroke with maximum displacement of 31.4 mm during 180° of cam rotation,
2. Return stroke for the next 150° of cam rotation,
3. Dwell for the remaining 30° of cam rotation.
The minimum radius of the cam is 15 mm and the Roller diameter of the follower is 10 mm.
The Axis of the roller follower is offset by 10 mm towards right from the axis of cam shaft.
Sol:
S = 31.4 mm
𝜃 = 180o
𝜃 = 150o
𝜃 = 30o
Generating Circle:
r=
r=
.
r=
r = 5𝑚𝑚
Page | 22
Now,
Construct a Cam Profile:
Pitch circle radius:
Pc = base circle + roller radius
Pc = 15 + 5 = 20mm
Page | 23
Uses:
Uses of Cycloidal motion type cam and follower:
1. High-Speed Weaving Looms Machines.
2. Yarn Feeding and Tension Control Systems.
3. Carton Sealing Machines.
4. High-Speed Pick and Place Robots.
5. Robotics.
Page | 24