International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Research Article
CAM FOLLOWER MECHANISM SIMULATION &
VERIFICATION OF CRITICAL JUMP SPEED ON SOFTWARE
1
B.S.Thakkar, 2S.A.Thakkar

Address for Correspondence

1
Asst. Prof., Mechanical Engineering Degree, PIET, Limda
2
Design Director, Zillion Technologies Ltd. India
ABSTRACT
The cam and the follower is one of the simplest as well as one of the most important mechanisms found in modern
machinery today. A cam is a rotating machine element which gives reciprocating or oscillating motions to another element
known as follower. Cams are also used to transform rotary motion into a translating or oscillating motion. One important
reason why cam mechanisms are preferred over other types that the use of cam makes it possible to obtain an unlimited
variety of motions and when certain basic requirements are followed, cams perform satisfactorily. In this paper efforts are
made to record critical jumping speed of the cam with the aid of Experimental Setup. The verification of critical jumping
speed of Cam & Follower mechanism is given through three methods:
1. By Analytical Calculations.
2. By Simulation Software.
3. By C-Programming.
The consequences are justified & percentage of deviation of results is also calculated.
I. INTRODUCTION II. EXPERIMENT SETUP
A cam is a rotating machine element which gives Here taking circular eccentric cam. The cam profile is
reciprocating or oscillating motions to another a circle. The center of rotation of the cam is often
element known as follower. Cams are also used to from the geometric center of the circle. The circular
transform rotary motion into a translating or cam produces a smooth form of motion called a
oscillating motion. The cam and the follower have a simple harmonic motion. These cams are often used
line contact and constitute a higher pair. The cams are to produce motion in pumps. Circular cams are often
usually rotated at uniform speed by a shaft, but the used to operate steam engine valves. As the cam is
follower motion is predetermined and will be symmetrical, the rise and fall motions are the same.
according to the shape of the cam. The cam and the
follower is one of the simplest as well as one of the
most important mechanisms found in modern
machinery today.
The requirements which are imposed on cams vary
from machine to machine because the requirements
depend not only on the speed of the cam, but also on
the kind of machine in which they are being used. In Figure 2 Cam-follower Setup
certain kind of wrapping machines, for example, the Here depicted fig.2 shows whole arrangement of
forces imposed on the material to be wrapped should circular eccentric cam-flat face follower, spring,
be kept as low as possible, but it doesnt matter if bearing block, coupling, D.C. motor, variable speed
these forces are applied suddenly, whereas in other D.C. motor.
machines it is very important for the proper A. Procedure:
performance of the machinery that the variation of 1. First of all make assembly of Circular
forces is smooth and gradual. Eccentric Cam and Flat face follower.
The basic limiting requirements are: 2. Then ON the supply.
1. Kind of time displacement diagrams. 3. Now, slowly increase the speed of the
2. Pressure angle variable speed D.C. motor.
3. Radius of curvature 4. Increase speed till the noise of jump just
4. The contact pressure between follower begins.
and cam 5. Note down that cam shaft rpm with the help
of Tachometer
TABLE 1: Cam Dimensions

TABLE 2: Follower Dimensions

B. Experimental Observation:
1. The Critical Jump Speed of Cam is 460 rpm.
III. ANALYTICAL CALCULATIONS
Figure 1 Cam Operated Valve A. Free body diagram:

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Inertia force = external forces

-my = fs f
F = my + fs
Fs = P + Ky
= P + Ke(1-cos)
= (m2 K)e cos + (P +Ke)
Thus, contact force is maximum when = 0deg
and minimum when =180deg. This force when less
than zero would result in the follower loosing contact
with the surface, resulting in jump. This would
happen, if the speed is increased beyond a particular
critical speed j and when the cam is at =180deg.
Substituting,
F = (m2 K)(-e) + P + Ke Figure 3.3 Part Model of Frame
= 2Ke + P - me2
Jump would begin when,
F = 0 = (j2 K )(-e) + P + Ke
j2 K) e = P + Ke
j2e Ke = P + Ke
j2 = (2Ke + P)/(me)
j = {(2Ke + P)/(me)}
Nj = (60j)/2
So, Analytical Jump Speed
j2 = (2Ke + P)/(me) =
(2*400*0.0075+5.5)/(0.895*0.0075) = 1713.22
j = 41.3910 rad/sec
Nj = (60*41.3910)/2 Figure 3.4 Exploded view of Assembly
Nj = 395.46 rpm
Thus, analytically obtained Critical jumping speed
is 395.46 rpm
Max. Follower Force acting on the Cam (Ff)
Ff = m.g + K.x= (0.895*9.81)+(400*0.015)
= 17.5 N
III. PART & ASSEMBLY MODEL
GENERATION
To carry out the simulation of critical jump speed
Cam & Follower mechanism, the 3D assembly of the
Cam & Follower setup is must. This can be done by
using modeling software. There are three major parts
in the setup as shown below.
A. Part Modeling: Figure 3.5 Three Dimensional view of the
Assembly
IV. SIMULATION
The Simulation is the process of designing a model of
a real system & conducting experiments on the model
for the purpose of understanding the behavior of the
system or of evaluating various strategies for the
operation of the system. It is a tool to predict the
behavior of the physical system under certain
conditions.
Figure 3.1: Part Model of Cam shaft Simulation thus involves with the experimentation of
computerized models of a system or process. A
simple example would be the simulation of a slider
crank mechanism. By simulating the movement of
slider crank, one would be in a position to know the
effects of the various parameters such as change in
obliquity ratio on the maximum velocity position of
the slider.
Simulation is normally attempted in cases where
simple mathematics would be unable to get to the
results. It generally involves complex problems in
cases where actual tests may not be practical.
Figure 3.2 Part Model of Follower
Simulation is a very general method of studying
problems. No formal procedures or routines can be

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developed for a simulation study. In many cases, even

the basic decision whether to simulate or not, is
difficult to make. As a guideline, some of the
elementary steps are shown.

Figure 4.3. Follower Connection in simulation

4. Select cam2 in the dialogue box.
5. Select Follower surface.
6. Front & Back reference require flat face
follower.
7. For front reference select point on follower
surface which is connected to cam.
8. For Back reference select point on back
surface of follower

Figure 4.1.Flow chart for General Simulation

Procedure
A. Simulation Procedure Using Simulation Software:
Simulation of Cam & Follower mechanism
simulation can be done using most recent simulation
software, here in this paper attempt is made to carry
out simulation using Pro-Engineering simulation
module called Pro-Mechanica.
B. Simulation Connection:
CASE: I Servo Motor at Variable Speed.

Figure 4.4 Considering Follower Gravity Force

(9810 mm/sec2)

Figure 4.2. Cam Connection in simulation.

1. Open assembly mode into mechanism.
2. First of all select new cam-connection from
connection.
3. Select cam surface in cam1. Figure 4.5 Considering Spring Specifications

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V. RESUL & DISCUSSIONS OF SIMULATION

MODEL
CASE: I Servo Motor at Variable Speed.
TABLE III: VARIABLE SPEED

Figure 4.6 Servo-motor at Variable speed.

9. Select servo motor from motors. Graph 1: At 1.05 sec connection force is zero and
10. In specification of velocity, insert Velocity jump will begin at speed of 402 rpm.
with time table gradually increases. For CASE: II Servo Motor at Constant Speed.
finding jump speed.

Graph 2: shows at jumping speed 402 rpm, spring

load is 11.5689129N.

Figure 4.7 Mechanism analysis

11. Select Mechanism analysis.
12. Take Dynamic type and take duration up to
the last time in the servo-motor table.
13. Run the model and graph will be created
CASE: II Servo Motor at Constant Speed.

Graph 3: shows at jumping speed 402 rpm,

Follower force comes 17.55689129 N.

Figure 4.8 Servo Motor at Constant Speed. Graph 4: shows at jumping speed 402 rpm,
1. After finding Jump speed, insert const magnitude
Follower Velocity is 334.4923958 mm/sec.
in the Velocity table.

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 International Journal of Advanced Engineering Research and Studies E-ISSN22498974

printf("\nEnter the max speed in rpm of the setup

:");
scanf("%f",&n1);
w=(2*3.14*n1)/60.00;
a=((2*k*e)+p)/(m*e);
wj=sqrt(a);
nj=(60.00*wj)/(2.00*3.14);
fp=fopen("graph.xls","w");
if(nj<=n1)
{
printf("\n speed \t\t contact force\n");
n=0;
for(n=0;n<=nj+1;n++)
Graph 5: shows at jumping speed 402 rpm, Cam {
Velocity is 400.4190737 mm/sec. w=(2*3.14*n)/60.00;
f=(2*k*e)+(p)-(m*e*w*w);
n1=(60.00*w)/(2.00*3.14);
printf("\n%f \t%f",n1,f);
fprintf(fp,"\t %f \t %f",n1,f);
}
fclose(fp);
}
else("at this input is not enough to creat jumping
speed");
getch();
}
Graph 8: shows at jumping speed comes at 396 rpm
from C Programming
Graph 6: shows at jumping speed 402 rpm, TABLE IV: RESULTS
Follower Acceleration is 12931.496314 (mm/sec2)

From above table, there are variations in jumping

speed by experimentally, analytically and simulation
model. The reason behind it is that friction is not
considered in analytically, simulation model and by C
programming whereas friction is considered in
experimental method.
VII. CONCLUSION
We conclude that a jumping speed is nearly about
Graph 7: shows at jumping speed 402 rpm, Cam 460 rpm with friction consideration and 400 rpm
Acceleration is 16192.16581(mm/sec2) without friction consideration. More power required
VI. C- PROGRAM OF ANALSIS in considering friction. So we need more power to
#include<stdio.h> overcome this friction so that speed is more in
#include<conio.h> experimentally.
#include<string.h> REFERENCES
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Note: This Paper proposes some important tasks which are necessary
in the modeling procedure of cams & Follower. These tasks are
modeling and virtual animation of the cam & Follower mechanism for
checking the critical jump speed of the mechanism. Techniques of
animation and checking the cam & Follower mechanism are
performed in Pro/ENGINEER Wildfire 3.0.

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