GRAPHICAL CONSTRUCTION OF CAM PROFILE

GRAPHICAL CONSTRUCTION OF CAM PROFILE

Contact Geometry of Roller Follower Contact Geometry of Roller Follower

ro

Si

rb

base circle
-
4 J Ju
rading rading ↓allower
of ruler
displacement
Roller Follower (no offset)
Contact Geometry of Flat-face Follower

Note that the cam profile is ‘tangent’

to the flat-face at this point.

Ri Si

Direction
rb
of cam rotation

Prime Circle
Try to sketch a cam (rb+ ro)
profile that is tangent to
all the roller followers

Flat-face Follower

Ri = rb + si

Perpendicular lines
(representing the
flat-face follower) BLANK PAGE
Ri

Direction
of cam rotation
Try to sketch a cam
profile that is tangent to
all the perpendicular
lines.

8
 GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e)

NOTES ON OFFSET FOLLOWERS:

• Cam systems are sometimes designed with offset followers.

• The intent is to reduce the lateral forces on a cam follower during

the rise portion of the cycle.

• Finding the optimum offset requires careful analysis.

CAM-AND-FOLLOWER SYSTEMS
• Careless design could worsen the situation.

10

GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e) GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e)

ROLLER FOLLOWER WITH AN OFFSET e Offset DRAWING STEPS: FOR ROLLER FOLLOWER WITH OFFSET e
• The offset is represented by an 1. Divide cam angle 360°) into number of equal portions, N (say 30°
offset circle. interval, N=12 portions)
Cam profile
Offset circle 2. Using displacement functions, calculate and tabulate s at every
+1
• The locations of roller center are interval (say 30°) s1, s2, s3 …..sN+1
found at different angular
3. Draw the base circle with given radius rb
positions based on offset circle.
2+ 4. Draw the prime circle, whose radius is rb+ r0
0 C
1
5. Draw an offset circle of radius e, centered at the cam rotation axis
2 6. Draw N lines tangent to the offset circle
3 4
3+
7. Starting from = 0°, use si from the intersection point on the prime
circle to determine the location of centre of the roller on
corresponding line, then draw a circle of r0 representing the roller on
4 + each line
8. Construct cam profile so that the profile curve is tangent to all the
roller circles

11 12
GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e) GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e)

DRAWING STEPS: FOR ROLLER FOLLOWER WITH OFFSET DRAWING STEPS: FOR ROLLER FOLLOWER WITH OFFSET
4. Draw the prime circle, whose radius is rb+ r0 5. Draw an offset circle of radius e, centered at the cam rotation axis

13 14

GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e) GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e)

DRAWING STEPS: FOR ROLLER FOLLOWER WITH OFFSET DRAWING STEPS: FOR ROLLER FOLLOWER WITH OFFSET
6. Draw N lines tangent to the offset circle 7. Starting from = 0°, use si from the intersection point on the prime
circle to determine the location of centre of the roller on corresponding
line, then draw a circle of r0 representing the roller on each line

+
+

+
+

+ +

+ +

+ +

15 16
GRAPHICAL CONSTRUCTION OF CAM PROFILE (ROLLER FOLLOWER WITH OFFSET e) CAM PROFILE DESIGN (ANALYTICAL METHOD)

DRAWING STEPS: FOR ROLLER FOLLOWER WITH OFFSET ANALYTICAL FORMULAS FOR COORDINATES OF A CAM PROFILE
8. Construct cam profile so that the profile curve is tangent to all the (FLAT-FACED TYPE FOLLOWER):
roller circles
The cam profile coordinates are (for zero offset):
Cam coordinates
ds
x  (rb  s ) Sin  Cos (5.35)
d
ds
y  (rb  s ) Cos  Sin
+
(5.36)
d
+
+

+
+

+ +

+ +

+ +

17 18

CAM PROFILE DESIGN (ANALYTICAL METHOD) CAM PROFILE DESIGN (ANALYTICAL METHOD)

CAM CURVATURE FROM EQ. (5.36)

Parametric expression for the radius of curvature,
dy  d 2s 
   rb  s  2  sin θ
dx dθ   dy dθ  
and
2 32
2
(5.61) dθ  dθ 
ρ .
dx dθ d 2 y 
dθ 2  dy dθ  d 2 x dθ 2  d2y  d 2s   ds d 3s 
TRANSLATING FLAT-FACED FOLLOWER 2
   rb  s  2  c o s θ    3  sin θ .
dθ  dθ   dθ dθ 
dx  d 2s 
   rb  s  2  c o s θ
and SUBSTITUTING INTO EQ. (5.61),

dθ  dθ 
d 2s
d 2x  d 2s   ds d 3s  ρ  rb  s  2 .
2
  rb  s  2  sin θ    3  co s θ . dθ
dθ  dθ   dθ dθ 
19 20
 CAM CURVATURE (RADIUS OF CURVATURE) CAM CURVATURE

AVOIDING ANY CUSPS AND CONCAVE PROFILE: Example: Minimum allowable base-circle radius
• When radius of curvature  = 0, a cusp (sharp corner) occurs.
Question:
• When  < 0, a concave portion of profile occurs (unfavorable for a flat- (Wilson & Sadler, 5.11 modified) Determine the minimum allowable base-circle radius of a
faced follower). cam based only on the given harmonic return portion of a motion program. The angular
range for the return is    5/3, with a span of 2/3, and the lift, L, of the flat-faced
• To avoid both problems, it is required that  > 0 (for flat-faced follower) follower is 2 cm.

For flat-faced follower, radius of curvature given by:

Solution:
d 2s The follower displacement is given by
Direction of   rb  s  2
d
L   (   )  
s  1  cos1.5(   )
increasing 
Cusp
d 2s s 1  cos   or
 2 / 3  
Straight line
(→ ∞
(
rb  s   0 2
d 2
Transition from
 d 2s 
concave to convex
rb   s  2  Differentiation gives
(→ ∞
 d 
ds d 2s
Convex
Concave
( d 2s  1.5 sin 1.5(   )  1.5 2 cos1.5(   )
( Define Q  s 
d 2
Then,
d d 2
Cam profile
rb  Q Finally, rb   Q max
21 22

CAM CURVATURE

Example (cont’d):

Question:
(Wilson & Sadler, 5.11 modified) Determine the minimum allowable base-circle radius of a
cam based only on the given harmonic return portion of a motion program. The angular
range for the return is    5/3, with a span of 2/3, and the lift, L, of the flat-faced
follower is 2 cm.

d 2s
Qs  1  cos1.5(   )  2.25 cos1.5(   )
d 2
 1  1.25 cos1.5(   )
 Q  1  1.25 cos1.5(   )

 Qmax  0.25
The condition rb   Q max gives rb  0.25
Therefore, rb  0.25 cm
23
 STATIC FORCE ANALYSIS OF MECHANISM

OUTLINE OF LECTURES:

• Force and moment

STATIC FORCE ANALYSIS OF MECHANISM • Free-body-diagram
• 2-D static equilibrium
• Static force analysis – examples
Wilson Pearson, Kinematics and Dynamics of Machinery SI, 1/e
Robert L. Norton, Kinematics and Dynamics of Machinery, SI Units, McGraw-Hill, 2013. Lecture covers: Chap 9, Sections 9.1 to 9.5
K. J. Waldron, G. L. Kinzel, Kinematics, dynamics, and design of machinery, Wiley, 2004
David H. Myszka, Machines & Mechanisms Applied Kinematic Analysis, International Edition, 4E, Pearson, 2011. Reading assignment: Chap 9, Sections 9.1 to 9.5
2

INTRODUCTION NEWTON’S LAWS OF MOTION

• All machines have mass, and if

parts of a machine are accelerating,
• First Law:
inertial forces will be associated with Every object remains
the motions. at rest or moves with
constant velocity,
• If the magnitudes of these inertial unless an unbalanced
forces are small relative to
force acts on it.
externally applied loads, then they
can be neglected in the force
analysis.
3 4
 NEWTON’S LAWS OF MOTION NEWTON’S SECOND LAW OF MOTION

• Second Law:  
An object that has an Translation:  F  ma
unbalanced force, has
acceleration that is Rotation about a fixed point:
(1) proportional to the force,
(2) in the direction of the M i  I
force, and
(3) inversely proportional to I  moment of inertia about
the mass of the object. a fixed point
5 6

NEWTON’S LAWS OF MOTION THE SCIENCE OF MECHANISMS/MECHANICS

• Statics deals with the equilibrium of

• Third Law: bodies, that are either at rest or
move with a constant velocity.

For every action, there • Dynamics deals with the

accelerated motion of bodies.
is an equal and
opposite reaction. • Kinematics is the study of motion,
quite apart from the forces which
produce that motion. More
particularly it is the study of position,
displacement, rotation, velocity, and
acceleration.
7 8
 FORCES AND MOMENTS FORCES AND MOMENTS

• Forces and moments r is position vector from
(couples) are vectors reference point to the point
 of force applied 
    F F

F  Fx i  Fy j  Fz k 
r
A reference point is needed 
r
to define the moment but
not for the force.
• Three components in   
i j k
x-, y- and z-directions in   
M  r  F  rx ry rz
Cartesian Coordinate Fx Fy Fz
System   
 ( ry Fz  rz Fy )i  ( rz Fx  rx Fz ) j  ( rx Fy  ry Fx )k
9 10

FREE-BODY DIAGRAM FREE BODY DIAGRAM

(a) A four-bar linkage.

• A Free-Body Diagram is a sketch or
drawing of part or all of a system, (b) Free-body
diagram of the
isolated to determine the nature of three moving
the forces acting on the body. links.

(c) Free-body
• An isolated part is separated from the diagram of two
system. connected links.

(d) Free-body
• All external forces and moments on diagram of a
the part are depicted. single link.
(e) Free-body
• Static/dynamic analysis is carried out. diagram of part of
11
a link. 12
 STATIC EQUILIBRIUM GRAPHICAL FORCE ANALYSIS

If a system is in • Graphical force analysis


static equilibrium ( a  0 and  = 0),
employs scaled free-body
diagrams and vector
then
 graphics in the determination
F  0 Resultant force = 0 of unknown machine forces.

 MG  0 Resultant moment = 0 • The graphical approach is
best suited for planar force
systems.
13 14

SPECIAL FREE-BODY DIAGRAMS TWO-FORCE MEMBER

When a link is subjected to

Two-force member
only two forces:
Three-force member
Two-force and a Couple Member - We refer to the link as a
“2-force member”
N-force members (N>3) are not of - The forces must be axial
much practical interest. (along the axis)
- The 2 forces must be
equal and opposite
15 16
 TWO-FORCE MEMBER THREE-FORCE MEMBER

A member subjected to three forces is in

equilibrium if and only if
(1) the resultant of the three forces is
zero, and
(2) the action lines of the forces all
intersect at the same point.

Two external forces are equal,

opposite and co-linear aligned
with the link.
17 18

THREE-FORCE MEMBER THREE-FORCE MEMBER

Force equilibrium condition states that

F1  F2  F3  0
Three forces form a
closed vector loop, a
force polygon.

All three external forces are co-

centered and form a close triangle
19 20
 TWO-FORCE AND A COUPLE MEMBER FRICTION

• Friction is everywhere in our

daily life and in machines.

• Friction can dissipate energy

by converting mechanical work
into heat.
Two external forces are • It reduces the efficiency of a
parallel, opposite and equal.
21
machine. 22

COULOMB FRICTION (SLIDING FRICTION)

A friction is called Coulomb Friction

when it is linearly proportional to the
normal contact force.
3 N
f = N f v 32
BLANK PAGE

 is the coefficient of friction 2

The direction of friction is opposite to

the relative velocity between two
contact surfaces.
23 24
 STEPS FOR STATIC FORCE ANALYSIS

1. Free individual body(s)

2. Draw applied force/moments

3. Draw assumed constraint forces

ANALYTICAL STATIC FORCE ANALYSIS
4. Write equilibrium equations for each free body
(total 3N)

5. Solve the equations for unknowns

Wilson Pearson, Kinematics and Dynamics of Machinery SI, 1/e

Robert L. Norton, Kinematics and Dynamics of Machinery, SI Units, McGraw-Hill, 2013.
K. J. Waldron, G. L. Kinzel, Kinematics, dynamics, and design of machinery, Wiley, 2004
David H. Myszka, Machines & Mechanisms Applied Kinematic Analysis, International Edition, 4E, Pearson, 2011.

26

STEPS FOR STATIC FORCE ANALYSIS 2-D STATIC FORCE ANALYSIS

1. Free individual body(s) Vector Equations:


2. Draw applied force/moments  i 0
F T j  0
i j
3. Draw assumed constraint forces

4. Write equilibrium equations for each free body

(total 3N)

5. Solve the equations for unknowns

27 28
 2-D STATIC FORCE ANALYSIS CONVENTION FOR FORCES IN FREE-BODY DIAGRAM

Vector Equations: 1. Direction & magnitude known  draw accordingly

2. Action line known, magnitude unknown  assume

 Fi  0 T j  0 direction along the action line
3. Action line unknown  assume a x-component & a y-
i j component

Scalar Equations:

Unknown
Assume a
Assume direction

Magnitude
 Fix  0
x-component &
along action line
• 3 equations for each free y-component

body
 Fiy  0
Assume a

Known
Draw accordingly x-component &
y-component
• If N bodies, 3N equations
T j  0 Known
Action line/Direction
Unknown

29 30

Y C
Example 9-1: Force Analysis of Four-Bar Linkage P = 120 lb
4
 40°
3
Analyze the linkage in the figure for the torque T12 required if P = 120 lb.
θ1
The driver link 2 is at an angle of 135° with the horizontal axis. B 3
D

2 135
θ1
Draw the free-body diagram of each link. ° E 4
X
A
T12
1

Y C
P = 120 lb
4
 40°
3
θ13
B D

2 135°
θ14
E
X
A
T12
1

31 32
 Unknown

Unknown
Y C Assume a Y C Assume a
Assume direction Assume direction

Magnitude

Magnitude
P = 120 lb along action line x-component & P = 120 lb along action line x-component &
4 y-component 4 y-component
 40°  40°
3 Assume a 3 Assume a

Known

Known
θ1
Draw accordingly x-component & θ1
Draw accordingly x-component &
B D y-component B D y-component
3 3

2 135 Known Unknown 2 135 Known Unknown

θ1 θ1
° E Action line/Direction ° E Action line/Direction
4 4
X X
A A
T12 T12
1 1

C
220 °
F34

4
P = 120 lb
D
F14y V

F14x

V
E
33 34
Unknown

Unknown
Y C Assume a Y C Assume a
Assume direction Assume direction
Magnitude

Magnitude
P = 120 lb along action line x-component & P = 120 lb along action line x-component &
4 y-component 4 y-component
 40°  40°
3 Assume a 3 Assume a
Known

Known
θ1
Draw accordingly x-component & θ1
Draw accordingly x-component &
B D y-component B D y-component
3 3

2 135 Known Unknown 2 135 Known Unknown

θ1 θ1
° E Action line/Direction ° E Action line/Direction
4 4
X X
A A
T12
1 F34 T12
1 F34
C C
22.65 ° 22.65 °
Equal and opposite
3 Equal and opposite (Newton’s 3rd Law) 3 Equal and opposite
C (Newton’s 3rd Law) C (Newton’s 3rd Law)
220 ° B 220 °
F23 F34 F23 F34

4 F23 4
P = 120 lb P = 120 lb
B
D 5.516 in D
F14y V 2 F14y V
A F12
F14x T12 F14x
V

V
E E
35 36
 Unknown
Y C Assume a
Assume direction
Example 9-2: Force Analysis of Drilling-Mud Pump

Magnitude
P = 120 lb along action line x-component &
4 y-component

3 40°
Assume a A pump used for pumping drilling mud in oil-well drilling has two double-acting cylinders. The
mechanism of such a pump is shown in Figure E9-2. On the upstroke, the gage pressure in the

Known
θ1
Draw accordingly x-component &
B 3
D y-component cylinder above the piston is 750 psi above atmospheric and on the bottom side is 5 psi below
2 135 Known Unknown
atmospheric. The frictional resistance from the piston and gland seals and the crosshead is
θ1
° E 4 Action line/Direction estimated to be total 12 lb. 6” D
X
A
T12
1 F34 Draw the free-body diagram of each link. Piston
C  =1.5 in
22.65 ° Total 4 Gland
Equal and opposite 30 lb
(Newton’s 3rd Law) 3 Equal and opposite
C (Newton’s 3rd Law) Cross-Head

B 220 °
F23 F34 C

F23 4 Connecting Rod

50 lb
P = 120 lb 36” 3
B O
5.516 in D x
2 F14y V
A F12 y 60° 45 lb
Crank
T12 F14x B A
Fig. E9-2 A drilling-mud pump 2
V

E 8” G
37 3” 38

6” D 6” D

Unknown
Assume direction Assume a

Magnitude
Piston Piston along action line x-component &
y-component
 =1.5 in  =1.5 in
Assume a
Total 4 Total 4

Known
Gland Gland Draw accordingly x-component &
30 lb 30 lb y-component
Cross-Head Cross-Head
Known Unknown
Action line/Direction
C C

Connecting Rod Connecting Rod

50 lb 50 lb
36” 3 36” 3
O O

60° 45 lb 60° 45 lb
Crank Crank
B A B A
2 2
8” G 8” G
3” 3”

39 40
 6” D 6” D

Unknown

Unknown
Assume direction Assume a Assume direction Assume a

Magnitude

Magnitude
Piston along action line x-component & Piston along action line x-component &
y-component y-component
 =1.5 in  =1.5 in
Assume a Assume a
Total 4 Total 4

Known

Known
Gland Draw accordingly x-component & Gland Draw accordingly x-component &
30 lb y-component 30 lb y-component
Cross-Head Cross-Head
Known Unknown Known Unknown
Action line/Direction F43y Action line/Direction
C C C
Connecting Rod 21,210 lb Area of piston top face AT = 32 Connecting Rod 21,210 lb
F43x
50 lb Net area of piston bottom face AB = AT 0.752 50 lb
36” 3 36” 3
O 750AT = 21,210 lb O

130 lb 5AB = 130 lb 130 lb

18”

4 4
1 Link 4 1 Link 4
60° 45 lb 30 lb = W4 60° 45 lb 30 lb = W4
Crank Crank 11.096°
B A 2 Given The gage pressure in the cylinder B A 2 Given
8” G
12 lb above the piston is 750 psi above 8” G
12 lb
3” F14 3” F14 50 lb = W3
atmospheric and on the bottom side
is 5 psi below atmospheric. 18”
F34x F34x
3 Link 3
C C
F23x
F34y F34y 2
B
41 F23y 42

6” D 6” D
Unknown

Unknown
Assume direction Assume a Assume direction Assume a
1
x
Magnitude

Magnitude
Piston along action line x-component & Piston along action line x-component &
y-component y-component
 =1.5 in  =1.5 in 2
Assume a y Assume a
Total 4 Total 4
Known

Known
Gland Draw accordingly x-component & Gland Draw accordingly x-component &
30 lb y-component 30 lb 3 y-component
Cross-Head Cross-Head
Known Unknown Known Unknown
F43y Action line/Direction F43y Action line/Direction
C C C C
Connecting Rod 21,210 lb Torque that Connecting Rod 21,210 lb
50 lb F43x must be 50 lb F43x
36” 3 applied to 36” 3
O O
the crank by
18” 18”
130 lb a motor 130 lb
4 F32y 4 F32y
1 Link 4 F32x 1 Link 4 F32x
60° 45 lb 30 lb = W4 F12y 60° 45 lb 30 lb = W4 F12y
Crank 11.096° Crank 11.096°
B A 2 Given B A B A 2 Given B A
8” G F12x 8” G F12x
3”
12 lb
F14 50 lb = W3 8” 2 G 3”
12 lb
F14 50 lb = W3 8” 2 G
18” 3” 18” 3”
T12 T12
F34x Link 3 F34x Link 3
3
3 Link 2 45 lb = W2
3
3 Link 2 45 lb = W2
C C
F23x F23x
F34y 2 F34y 2
B B
F23y 43 F23y 44
Example 9-3: Force Analysis of Spur Gears (Wilson 6.15)
A B C
For the three gears shown in Figure E9-5-1, gear 1, the driver, rotates at 1000 rev/min clockwise
and delivers 30 kW. Gear 1 has a module of 10mm, a pressure angle of 20o, and 35 teeth, while
gear 2 has 45 teeth, and gear 3 has 60 teeth. 1
y
2
Draw the free-body diagram of each gear. x 3

A B C

y
1
2
x 3

Fig. E9-5-1 A gear train of three spur gears

45 46
Unknown

Unknown
Assume direction Assume a Assume direction Assume a
Magnitude

Magnitude
along action line x-component & along action line x-component &
y-component y-component
A B C A B C
Assume a Assume a
Known

Known
Draw accordingly x-component & Draw accordingly x-component &
y y-component y y-component
1 1
2 Known 2 Known
Unknown Unknown
x 3 Action line/Direction x 3 Action line/Direction

Gear 1

∅
TA Fr1-2

vv
FAx +

v
v
FAy
Ft1-2

47 48
 Unknown

Unknown
Assume direction Assume a Assume direction Assume a

Magnitude

Magnitude
along action line x-component & along action line x-component &
y-component y-component
A B C A B C
Assume a Assume a

Known

Known
Draw accordingly x-component & Draw accordingly x-component &
y y-component y y-component
1 1
2 Known 2 Known
Unknown Unknown
x 3 Action line/Direction x 3 Action line/Direction

Gear 1 Gear 2 Gear 1 Gear 2 Gear 3

Ft1-2 Ft2-3 Ft1-2 Ft2-3 ∅
∅ ∅
TC
TA Fr1-2 Fr2-3 TA Fr1-2 Fr2-3
vv

vv
FAx + v FBx v FAx + v FBx v +

v
v

v
v

v
+ + v
v

v
v

v
v v v v
Fr1-2 Fr1-2 Fr2-3 FCx FCy
FAy ∅ ∅ FAy ∅ ∅
Ft1-2 Ft1-2
FBy FBy Ft2-3

49 50
Unknown

Assume direction Assume a

Magnitude

along action line x-component &

y-component
A B C
Assume a
Known

Draw accordingly x-component &

y y-component
1
2 Known Unknown
x 3 Action line/Direction

Gear 1 Gear 2 Gear 3

Ft1-2 Ft2-3 ∅
∅
TC
TA Fr1-2 Fr2-3
vv

FAx v FBx v
v

+ +
v
v

+ v
v

v v
Fr1-2 Fr2-3 FCx FCy
FAy ∅ ∅
Ft1-2
FBy Ft2-3

x y
51