Outline

ME 2201: Kinematics and Dynamics of Machinery

August-November 2023

Manoj Pandey

Cam Synthesis

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 Cam Design

1 Classification of Cam and Follower

2 Cam Terminology

3 Follower motion
Graphical Methods
Analytical Methods

4 Graphical Cam synthesis

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 Cam Types

Introduction

Cam-follower systems frequently used in machines

> Valves in automotive engines are opened/closed by cams
Easier to design given a specific output function when compared
to linkages
> Difficult and more expensive to make
A form of degenerate four-bar linkage
> Link lengths are variable and hence the ability to generate complex
motions if needed
Cam-follower system has a “higher” pair joint

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 Cam Types

Equivalence to 4-bar

From “Design of Machinery” by R. L. Norton

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 Cam Types

Follower Classification

Type of motion
Radial translating follower
Offset translating follower
Oscillating follower
Nature of contact
Knife-edge
Flat-face
Roller
Spherical

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 Cam Types

Follower types

Knife edge and flat-face

From “Theory of Mechanisms and Machines” by Ghosh and Mallik

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 Cam Types

Types ...

Roller and spherical face

From “Theory of Mechanisms and Machines” by Ghosh and Mallik

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 Cam Types

Other cam-follower systems

Wedge and Cylindrical Cams

From “Theory of Mechanisms and Machines” by Ghosh and Mallik

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 Cam Types

Positive-acting Cams

In all designs shown so far follower requires spring force to

maintain contact
Positive-acting cams do not require springs

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 Cam Types

Some manufactured cams

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 Cam Types

Some manufactured cams

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 Cam Types

Roller follower

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 Cam Types

Flat face follower

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 Nomenclature

Cam Language

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 Nomenclature

Terms

Base Circle
Smallest circle drawn tangent to cam profile from cam centre
Trace Point
Theoretical point on follower with its motion describing the
movement of follower
Roller follower: Roller centre
Flat-face: Point of contact between cam and follower when cam is at
its base circle
Pitch Curve
Curve generated by locus of trace point holding cam fixed

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 Nomenclature

Base circle and Pitch curve

Pitch curve for roller follower

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 Nomenclature

More terms

Pressure angle
Angle between the follower movement direction and normal to pitch
curve
Greater the pressure angle larger is the side thrust
For low speed cams with oscillating followers pressure angle should
be less than 45◦
For translating followers pressure angle should be less than 30◦
Pressure angle can be reduced by increasing the size of cam
Can also be done by offset of the follower

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 Nomenclature

Pressure angle

Pitch curve for roller follower

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 Nomenclature

More ...

Pitch point
The point of maximum pressure angle
Circle drawn with centre at cam centre to pass through pitch point
is called pitch circle
Prime Circle
Smallest circle that can be drawn (with centre at cam centre) that is
tangential to pitch curve

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 Nomenclature

Pitch point

Pitch curve for roller follower

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 Nomenclature

Pitch point and circle

Pitch curve for roller follower

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 Motion Graphical

Follower motion description

Cam is assumed to rotate at constant speed

Movement of follower for one complete rotation of cam is called
displacement diagram
Maximum follower displacement is called lift
In general there are 4 parts: rise, dwell, return and another dwell

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 Motion Graphical

Displacement diagram

Inflexion points correspond to maximum and minimum velocities

of follower
They correspond to the pitch points
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 Motion Graphical

Construction of diagram

Displacement profile for rise and return can be based on

Uniform motion and its modifications
Simple harmonic motion
Uniform acceleration motion
Cycloidal motion
We now look at graphical means to construct these

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 Motion Graphical

Uniform motion

We illustrate the construction procedure with lift being L and rise

angle being θri
Uniform motion implies velocity of follower is constant
Cam starts from y=0 and θ = 0 and at the end of the rise period
y=L and θ = θri
For uniform velocity the displacement is simply a straight line
joining the two endpoints

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 Motion Graphical

Uniform motion ...

Instantaneous change in velocity at the beginning and end of rise

To avoid this a tangential curve from the straight line portion is
drawn

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 Motion Graphical

Simple harmonic motion

Angle of rise θri can be divided into say 6 or 8 segments

Draw a semi-circle of diameter L and divide the circular portion
into same number of segments

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 Motion Graphical

Simple harmonic motion

Horizontal lines are drawn from the points obtained on the

semi-circle
It meets the corresponding vertical lines along θ axis
Finite velocity,acceleration and jerk

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 Motion Graphical

Uniform acceleration

One half of lift is uniform acceleration and the other uniform

deceleration
Mid-point has a sudden change in acceleration

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 Motion Graphical

Uniform acceleration

Inclined line divided into 18 (my friend was correct) divisions as

shown
We go 1, 4, 9 for the first half and then 9,4,1 for the second half

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 Motion Graphical

Unequal acceleration/deceleration

The acceleration rate is 2 times the deceleration rate

So for one-third of lift acceleration phase followed by deceleration
phase
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 Motion Graphical

Cycloidal motion

Cycloid is the locus of a point on a circle as it rolls on a line

L
We draw a circle on top right as shown of radius 2π

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 Motion Graphical

Cycloidal motion

Circle divided into 6 parts

Projections of points 1-6 are taken on the vertical diameter
Lines parallel to OA are drawn; intersection of vertical lines with
these yield displacements

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 Motion Analysis

Analytical expressions for displacements

Detailed discussion for uniform acceleration/deceleration

During acceleration y = Cθ2 , 0 ≤ θ ≤ θ2ri
Since y = L2 when θ = θ2ri we get C = 2L( θθri )2
4Lω
The velocity is ẏ = θri2
θ where θ̇ = ω is angular velocity of cam
and is constant
θri
Maximum velocity of follower occurs at θ = 2 which leads to
ẏmax = 2Lω
θri
4L 2
Acceleration ÿ = θri2
ω = constant

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 Motion Analysis

Retardation phase

We now let y = C1 + C2 θ + C2 θ2 for θ2ri ≤ θ ≤ θri

We have the following three conditions for the three constants
At θ = θri we have y = L
At θ = θri ẏ = 0 assuming a dwell at end of rise
At θ = θ2ri ẏ = 2Lω
θri assuming velocity continuity
4L
This leads to C1 = −L, C2 = θri and C3 = − 2L
θ2 ri
θ 2
This gives y = L{1 − 2(1 − θri ) }
4Lω θ
The velocity is then given by ẏ = θri (1 − θri ) and acceleration is
ÿ = − 4L
θ2
ω2
ri

Note that the jerk is infinite at θ = 0, θ2ri , θri

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 Motion Analysis

Other motions

Uniform motion: y = L θθri for 0 ≤ θ ≤ θri

Simple harmonic motion: y = L2 {1 − cos( πθ
θri )} for 0 ≤ θ ≤ θri
1
Cycloidal motion: y = L{ θθri − 2π sin( 2πθ
θri )}for 0 ≤ θ ≤ θri

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 Motion Analysis

Advanced Curves

Basic follower motions discussed so far inadequate for smooth

operation
Combine basic curves matching velocities and accelerations at
junction points
Represent the follower motion by higher order polynomial curves
y = C0 + C1 θ + C2 θ2 + C3 θ3 + ... + Cn θn
The number of terms used is usually six for 6 conditions
y = ẏ = ÿ = 0 at θ = 0 and θ = θri
With first 6 polynomial powers leads to
y = 10L( θθri )3 − 15L( θθri )4 + 6L( θθri )5
Called the 3-4-5 curve

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 Graphical

Radial Follower Design

A radial flat-face follower has a lift of 3 cm

Displacement diagram components are
Rise for 180◦ : Simple harmonic motion
Dwell for 30◦
Return for 120◦ : Simple harmonic motion
Dwell for 30◦
Assume that the base circle radius of cam is 3 cm and it rotates
anti-clockwise

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 Graphical

Synthesized Cam profile

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 Graphical

Offset Follower Cam design

Translating roller follower is offset to left of cam centre by 1.5 cm

and has a lift of 4 cm
Displacement diagram components are
Rise for 150◦ : Parabolic motion
Dwell for 30◦
Return for 150◦ : Parabolic motion
Dwell for 30◦
Assume base circle radius is 3 cm and roller radius is 0.5 cm
Cam rotates clockwise

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 Graphical

Follower diagram

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 Graphical

Synthesis of cam

Principle of inversion used with cam fixed and follower rotating

anti-clockwise
Remember that the follower axis is always at a distance of 1.5 cm
from cam centre
If cam is held fixed the follower translation axis will be tangential to
the offset circle with centre at cam centre and radius equal to the
offset
We first draw the offset circle and divide it into intervals as used
for follower diagram

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 Graphical

Cam designed

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