DEVELOPMENT OF CAM PROFILES

Introduction
A cam mechanism usually consists of two moving elements, the cam and the follower, mounted on
a fixed frame. The cams are usually rotated at uniform speed by a shaft, but the follower motion is
predetermined and will vary according to the shape of the cam. Cam mechanisms are used
extensively in modern machinery. Cam devices are versatile, and almost any arbitrarily -specified
motion can be obtained.

The cam acts as a driving member and is made to have miscellaneous boundary (usually curved
shape) surface in order to transmit desired motion to the corresponding follower (the driven
member) by a direct contact. The cam shape is like a disc with some projection on its face. The cam
transmits the desired motion (reciprocating or oscillatory) to the follower as shown in Figure 3-1.

Figure 3-1: Cam and follower

Cams are widely employed in the operations of most machineries because of its accurate and
efficient transmission of motion, velocity and acceleration. The applications include operating inlet
and exhaust valves in I.C. engines, pumps, printing machines, etc.
Classification of Cam Mechanisms
Cam mechanisms can be classified into various types based on input motion of cam and output
motion of follower.

1. Rotating cam-translating follower mechanisms. The rotary motion of the cam is transformed
into a translating motion of the follower. Example is shown in Figure 3-2(a).

2. Rotating cam-oscillating/rotating follower mechanism. The rotary motion of the cam is

transformed into a predetermined oscillatory motion of the follower. Example is shown in
Figure 3-2(b)
3. Translating cam-translating follower mechanism. Both the cam and follower have
translation motion. Example is shown in Figure 3-2(c).
4. Stationary cam-rotating follower mechanism. The follower system revolves around a
stationary cam profile.
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Figure 3-2: Modes of Input/Output Motion of a cam mechanism

Types of Followers
1. According to the construction of contact surface

(a) Knife edge follower: When the contacting end of the follower has a sharp knife
edge, it is called a knife edge follower as shown in Figure 3-8(a).
(b) Roller follower: When the contacting end of the follower is a roller, it is called a
roller follower, as shown in Figure 3-8(b).
(c) Flat faced follower: When the contacting end of the follower is a perfectly flat face,
it is called a flat-faced follower, as shown in Figure 3-8(c).
(d) Spherical faced follower: When the contacting end of the follower is of spherical
shape, it is called a spherical faced follower, as shown in Figure 3-8(d).

Figure 3-8: Classification of followers based on contact surface

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 2. According to the types of motions

(a) Translating or reciprocating follower: When the follower reciprocates in guides

as the cam rotates uniformly, it is known as reciprocating or translating follower.
The followers as shown in Figure 3-8(a) to (d) are all reciprocating or translating
followers.
(b) Oscillating or rotating follower: When the uniform rotary motion of the cam is
converted into predetermined oscillatory motion of the follower, it is called
oscillating or rotating follower. The follower, as shown in Figure 3 -8 (e), is an
oscillating or rotating follower.

Motion of the Follower

The follower, during its travel, may have one of the following motions.

a) Uniform velocity,
b) Simple harmonic motion,
c) Uniform acceleration and retardation, and
d) Cycloidal motion.

We shall now discuss the displacement, velocity and acceleration diagrams for the cam when the
follower moves with the above-mentioned motions. The cam profiles will be constructed for
different types of followers with different types of motions. The problem of the designer is to
construct the cam profile necessary to obtain the desired motion of the follower.

Displacement diagrams
The problem here is to graphically determine the profile of the cam that will transmit the desired
motion to the follower. In order to draw the cam profile for a radial cam, first of all the displacement
diagram for the given motion of the follower is drawn.
During the rotation of a cam through one cycle, the follower executes a series of events as
demonstrated in graphic form in the displacement diagram. A displacement diagram is a curve
showing the displacement of the follower as ordinates erected on a baseline that represents one
revolution of the cam. When the cam turns through one motion cycle, the follower executes a series
of events consisting of rises, dwells and returns.

Rise is the motion of the follower away from the cam center. The total rise is called the lift. Dwell
is the motion during which the follower is at rest; and return is the motion of the follower towards
the cam center. By placing the follower in its proper position in a number of successive angular
positions, the profile of the working surface of the cam can be drawn.

The follower displacement should be drawn to scale but any convenient length can be used to
represent 360° of the cam rotations. The abscissa (base) represents the time (i.e., the number of
seconds required for the cam to complete one revolution) or it may represent the angular
displacement of the cam in degrees. The ordinate represents the displacement of the follower.

Since the motion of the follower is of primary importance, its rate of speed and its various positions
should be carefully planned in a displacement diagram before the cam profile is constructed.

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Major types of follower motion:

a) Uniform velocity
b) Simple harmonic motion
c) Uniform acceleration and retardation

In constructing the cam profile, the principle of kinematic inversion is used, i.e., the cam is imagined
to be stationary and the follower is allowed to rotate in the opposite direction to the true cam rotation
thus preserving the correct sequence when motion of the cam takes place. A decent cam profile can
be obtained by using many positions.

Displacement Diagram when the Follower Moves with Uniform Velocity

In a uniform velocity; equal displacements of the follower during equal periods of time (equal
change of cam angular displacement). Since the follower moves with uniform velocity during its
rise and return/fall stroke, therefore the slope of the displacement curves must be constant. In
other words, slopes must be straight lines. At times, 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,
as shown in Figure 3-9.

Figure 3-9: Displacement diagram when the follower moves with uniform velocity.

Displacement Diagram when the Follower Moves with Simple Harmonic Motion
The displacement diagram when the follower moves with simple harmonic motion is shown in
Figure 3-10. This motion provides the smoothest change of motion in the follower. For SHM, the
velocity and acceleration are both smooth and no discontinuities.

Figure 3-10: Displacement diagram when the follower moves with simple harmonic motion.
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 The displacement diagram is drawn as follows:

1. Draw a semi-circle on the follower stroke as diameter.

2. Divide the semi-circle into any number of even equal parts (say eight).
3. Divide the angular displacements of the cam during out stroke and return stroke into the
same number of equal parts.
4. The displacement diagram is obtained by projecting the points as shown in Figure 3-10.

Displacement Diagram when the Follower Moves with Uniform Acceleration and
Retardation
The displacement diagram when the follower moves with uniform acceleration and retardation are
shown in Figure 3-11.
We see that the displacement diagram consists of a parabolic curve and may be drawn as discussed
below:

5. Divide the angular displacement of the cam during outstroke (θO) into any even number of
equal parts (say eight) and draw vertical lines through these points as shown in Figure 3-11.
6. Divide the stroke of the follower (S) into the same number of equal even parts.
7. Join Aa to intersect the vertical line through point 1 at B. Similarly, obtain the other points
C, D etc. as shown in Figure 3-11. Now join these points to obtain the parabolic curve for
the out stroke of the follower.
8. In the similar way as discussed above, the displacement diagram for the follower during
return stroke may be drawn.

Figure 3-11: Displacement diagram when the follower moves with uniform acceleration and
retardation.

Since the acceleration and retardation are uniform, therefore the velocity varies directly with the
time.

Construction of Cam Profiles

In order to draw the cam profile for a radial cam, first of all the displacement diagram for the given
motion of the follower is drawn. Then by constructing the follower in its proper position at each
angular position, the profile of the working surface of the cam is drawn. The construction of cam
profiles for different types of followers with different types of motions arediscussed in the following
examples.
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 Example 3-1

A cam is to give the following motion to a knife-edged follower:

1. 0 ° - 60°, Outstroke
2. 60 ° - 90°, Top dwell
3. 90 ° - 150°, Return stroke, and
4. 150 ° - 360°, Bottom dwell

The stroke of the follower is 40 mm and the minimum radius of the cam is 50 mm. The follower
moves with uniform velocity during both the outstroke and return strokes. Draw the follower
displacement diagram and profile of the cam assuming the axis of the follower passes through the
axis of the cam shaft.

Construction

First of all, the displacement diagram, as shown in Figure 3-12, is drawn as discussed in the
following steps:

1. Draw a horizontal line AX = 360° to some suitable scale. On this line, mark AS = 60° to
represent outstroke of the follower, ST = 30° to represent dwell, TP = 60° to represent return
stroke and PX = 210° to represent dwell.

Figure 3-12: Displacement diagram of a knife edge follower with uniform velocity

2. Draw vertical line AY equal to the stroke of the follower (i.e., 40 mm) and complete the
rectangle as shown in Figure 3-12.
3. Divide the angular displacement during outstroke and return stroke into any equal number
of even parts (say six) and draw vertical lines through each point.
4. Since the follower moves with uniform velocity during outstroke and return stroke, therefore
the displacement diagram consists of straight lines. Join AG and HP.
5. The complete displacement diagram is shown by AGHPX in Figure 3-12.

The cam profile is constructed based on the following steps;

1. Draw a base circle with radius equal to the minimum radius of the cam (i.e. 50 mm) with O
as centre. Draw the two centerlines of the cam to locate its center of rotation.

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 2. Since the axis of the follower passes through the axis of the cam shaft, therefore mark trace
point A, as shown in Figure 3-13.
3. From OA, mark angle AOS = 60° to represent outstroke, angle SOT = 30° to represent dwell
and angle TOP = 60° to represent return stroke.
4. Divide the angular displacements during outstroke and return stroke (i.e. angle AOS and
angle TOP) into the same number of equal even parts as in displacement diagram.
5. Join the points 1, 2, 3 ...etc. and 0′ ,1′ , 2′ , 3′ , ... etc. with centre O and produce beyond
the base circle as shown in Figure 3-13.
6. Now set off 1B, 2C, 3D ... etc. and 0′ H,1′ J ... etc. from the displacement diagram.
7. Join the points A, B, C,... M, N, P with a smooth curve. The curve AGHPA is the complete
profile of the cam when follower moves with uniform velocity during both the outstroke and
return strokes.

Figure 3-13: Cam profile when the axis of the knife edge follower with uniform motion Notes:

The points B, C, D..... L, M, N may also be obtained as follows:

1. Mark AY = 40 mm on the axis of the follower, and set of Ab, Ac, Ad... etc. equal to the
distances 1B, 2C, 3D... etc. as in displacement diagram.
2. From the centre of the cam O, draw arcs with radii Ob, Oc, Od etc. The arcs intersect the
produced lines O1, O2... etc. at B, C, D ... L, M, N.

Example 3-2

A cam is to be designed for a knife edge follower with the following data:

1. Cam lift = 40 mm during 90° of cam rotation with simple harmonic motion.
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 2. Dwell for the next 30°.
3. During the next 60° of cam rotation, the follower returns to its original position with simple
harmonic motion.
4. Dwell during the remaining 180°.
Draw the displacement diagram of the follower and profile of the cam.

Solution

First of all, the displacement diagram, as shown in , is drawn as discussed in the following steps:

1. Draw horizontal line AX = 360° to some suitable scale. On this line, mark AS = 90° to
represent out stroke; SR = 30° to represent dwell; RP = 60° to represent return stroke and
PX = 180° to represent dwell.
2. Draw vertical line AY = 40 mm to represent the cam lift or stroke of the follower and
complete the rectangle as shown in Figure 3-15.

Figure 3-15: Displacement diagram of a knife edge follower with SHM motion

3. Divide the angular displacement during out stroke and return stroke into any equal number
of even parts (say six) and draw vertical lines through each point.
4. Since the follower moves with simple harmonic motion, therefore draw a semicircle with
AY as diameter and divide into six equal parts.
5. From points a, b, c ... etc. draw horizontal lines intersecting the vertical lines drawn through
1, 2, 3 ... etc. and 0′ ,1′, 2′ ...etc. at B, C, D ... M, N, P.
6. Join the points A, B, C ... etc. with a smooth curve as shown in Figure 3-15. This is the
required displacement diagram.

The profile of the cam when the line of stroke of the follower passes through the axis of the cam
shaft, as shown in Figure 3-16, is drawn in the similar way as is discussed in Example 3-1.

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 Figure 3-16: Cam profile of a inline knife edge follower with SHM motion

Example 3-3

A cam, with a minimum radius of 50 mm, rotating clockwise at a uniform speed, is required to give
a knife edge follower the motion as described below:

1. To move outwards through 40 mm during 100° rotation of the cam;

2. To dwell for next 80°;
3. To return to its starting position during next 90°, and
4. To dwell for the rest period of a revolution i.e. 90°.

Draw the displacement diagram for one complete revolution of the cam and the profile of the cam.
The displacement of the follower is to take place with uniform acceleration and uniform retardation.

Solution.

First of all, the displacement diagram, as shown in Figure 3-18, is drawn as discussed in the
following steps:

1. Draw a horizontal line ASTPQ such that AS represents the angular displacement of the cam
during outward stroke (i.e., 100°) to some suitable scale. The line ST represents the dwell
period of 80° after outward stroke. The line TP represents the angular displacement of the

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 cam during return stroke (i.e., 90°) and the line PQ represents the dwell period of 90° after
return stroke.
2. Divide AS and TP into any number of equal even parts (say six).
3. Draw vertical lines through points 0, 1, 2, 3 etc. and equal to the lift of the valve i.e., 40 mm.
4. Divide the vertical lines 3-f and 3′- f′ into six equal parts as shown by points a, b, c . . . and
a′, b′, c′ . . . in Figure 3-18.
5. Since the follower moves with equal uniform acceleration and uniform retardation, therefore
the displacement diagram of the outward and return stroke consists of a double parabola.
6. Join Aa, Ab and Ac intersecting the vertical lines through 1, 2 and 3 at B, C and D
respectively.
7. Join the points B, C and D with a smooth curve. This is the required parabola for the half
outstroke of the valve. Similarly, the other curves may be drawn as shown in Figure 3-18.
8. The curve A B C . . . N P Q is the required displacement diagram.

Figure 3-18: Displacement diagrams of a knife edge follower with UAR motion
The profile of the cam when the line of stroke of the follower passes through the centre of cam
shaft, as shown in Figure 3-19, may be drawn as discussed in the following steps:

1. Draw a base circle with centre O and radius 50 mm (equal to minimum radius of the cam). 2.
Divide the base circle such that angle AOS = 100°; angle SOT = 80° and angle TOP = 90°.
3. Divide angles AOS and TOP into the same number of equal even parts as in displacement
diagram (i.e. six parts).
4. Join the points 1, 2, 3 . . . and 1′, 2′, 3′, . . . with centre O and produce these lines beyond
the base circle.
5. From points 1, 2, 3 . . . and 1′, 2′, 3′, . . . mark the displacements 1B, 2C, 3D . . . etc. as
measured from the displacement diagram.
6. Join the points A, B, C . . . M, N, P with a smooth curve as shown in Figure 3-19. This is
the required profile of the cam.

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 Figure 3-19: Cam profile of an inline knife edge follower with UAR

Example 3-4

A cam, with a minimum radius of 25 mm, rotating clockwise at a uniform speed is to be designed
to give a roller follower, at the end of a valve rod, motion described below:

1. To raise the valve through 50 mm during 120° rotation of the cam,

2. To keep the valve fully raised through next 30°;
3. To lower the valve during next 60°; and
4. To keep the valve closed during rest of the revolution i.e., 150°;

The diameter of the roller is 20 mm and the diameter of the cam shaft is 25 mm.
Draw the displacement diagram for one complete revolution of the cam and the
profile of the cam. The displacement of the valve, while being raised and
lowered, is to take place with simple harmonic motion.

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Solution

Since the valve is being raised and lowered with simple harmonic motion, therefore the
displacement diagram, as shown in Figure 3-21, is drawn in the similar manner as discussed in the
previous example.

Figure 3-21: Displacement diagram of a roller follower with SHM motion

The profile of the cam, as shown in Figure 3-22, is drawn as discussed in the following steps:

1. Draw a base circle with centre O and radius equal to the minimum radius of the cam (i.e.,
25 mm).
2. Draw a prime circle with centre O and radius,
OA = min. radius of cam + 0.5 diameter of roller = 25 + 0.5 x 20 = 35 mm.
3. Draw angle AOS = 120° to represent raising or out stroke of the valve, angle SOT = 30° to
represent dwell and angle TOP = 60° to represent lowering or return stroke of the valve.
4. Divide the angular displacements of the cam during raising and lowering of the valve (i.e.,
angle AOS and TOP) into the same number of equal even parts as in displacement diagram.
5. Join the points 1, 2, 3, etc. with the centre O and produce the lines beyond prime circle as
shown in Figure 3-22.
6. Set off 1B, 2C, 3D etc. equal to the displacements from displacement diagram.
7. Join the points A, B, C ... N, P, A. The curve drawn through these points is known as pitch
curve.
8. From the points A, B, C ... N, P, draw circles of radius equal to the radius of the roller.
9. Join the bottoms of the circles with a smooth curve as shown in Figure 3-22. This is the
required profile of the cam.

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Figure 3-22: Cam profile of an inline roller follower with SHM motion.

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 Assignment 3
1. A cam, with a minimum radius of 50 mm, rotating clockwise at a uniform speed, is required
to give a knife edge follower the motion as described below:
i. To rise through 50 mm during the first 120° rotation of the cam
ii. To dwell for next 60°
iii. To fall during next 120°, and
iv. To dwell for the rest period of a revolution i.e. 60°.
Draw the displacement of the follower and profile of the cam when the line of stroke of the
follower passes through the center of the cam shaft. The displacement of the follower is to take
place with uniform acceleration and uniform retardation.

2. Draw the follower displacement diagram and cam profile of a disc plate cam which rotates
clockwise and imparts the following vertical motion to a roller follower.
• 0° – 160°, Rise 62 mm with simple harmonic motion
• 160° – 240°, Top dwell
• 240° – 300°, Fall 62 mm with uniform velocity
• 300° – 360°, bottom dwell

The diameter of the roller is 10 mm, the least radius of the cam is 30 mm and the cam shaft
diameter is 20 mm.

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