Cylindrical Cam Design PDF

DESIGN AND ANALYSIS OF CYLINDRICAL
CAM WITH ROLLER FOLLOWER ROTARY

INDEXING TABLE
By
PANCHAL VIKRAM JAYANTILAL
Enrollment No: 120030708012
Ravi C. Patel
Assistant Professor
M. Tech. Mechanical (CAD/CAM)
A Thesis Submitted to
Gujarat Technological University in Partial
Fulfillment of the Requirements for
The Degree of Master of Engineering in
Mechanical (CAD/CAM)
June 2014
ATMIYA INSTITUTE OF TECHNOLOGY & SCIENCE

RAJKOT - GUJARAT
CERTIFICATE
This is to certify that research work embodied in this thesis enti
titled “Design and
Analysis of Cylindrical Cam with Roller Follower Rotary Indexing Table”
Table was
carried out by VIKRAM JAYANTILAL PANCHAL (Enrollment No.
120030708012) Studying at Atmiya Institute of Technology & Science (A.I.T.S - 003)
for partial fulfillment of Master of Engineering degree to be awarded by Gujarat
Technological University.
University This research work has been carriied out under my
supervision and is to my
m satisfaction.
Date:
Place: Rajkot
Signature and Name of Supervisor Signature and Name

N of Principal
Ravi C. Patel Dr. G.D.Acharya

Acharya
Seal of Institute
i
COMPLIANCE CERTIFICATE
E
This is to certify thaat research work embodied in this thesis
sis entitled “Design and
Table was
carried out by VIKRAM JAYANTILAL PANCHAL (Enrollment
Enrollment No.
No 120030708012)
Studying at Atmiya Institute of Technology & Science (A.I.T.S - 003) for partial fulfillment
of Master
aster of Engineering degree to be awarded by Gujarat Techno
hnological University. He
has complied with the comments given byy the Dissertation Phase-I
Phase as well as Mid
Semester Thesis Review
viewer to my satisfaction.
Date:
Place: Rajkot
Signature and Name of Student Signaturre and Name of Guide

Vikram Jayantilal
ayantilal Panchal Ravi C. Patel
PAP
PAPER PUBLICATION CERTIFICA
CATE
This is to certify thaat research work embodied in this thesis entitled “Design and
Table was
carried out by VIKRAM JAYANTILAL
LAL PANCHAL (Enrollment No.
120030708012) Studying at Atmiya Institute of Technology & Science (A.I.T.S - 003) for
partial fulfillment of Master of Engineering degree to be awarded by Gujarat
Technological Universsity, h a s p u b l i s h e d article entitled “Review on Selection of
Rotary indexing mechanism for high productivity” f o r publication by the
International Journal of For Technology Studies att ISSN:2348 1439,
1439 Vol-1, Issue-2, in
January 2014.
Date:
Place: Rajkot
Signature and Name of Student Signature and Name of Guide
Vikram Jayantilal Panchal Ravi C. Patel
Signature and Name of Principal

Dr. G.D.Acharya
Seal of Institute
ii
TH
THESIS APPROVAL
L CERTIFICATE
This is to certify thatt research work embodied in this thesis “D

Design and Analysis of
Cylindrical Cam with Roller Follower Rotary Indexing Table”
Table was carried out b y
Mr. VIKRAM JAYANTILAL PANCHAL (Enrollment No. 1220030708012) Studying
at Atmiya Institute of Technology & Science (A.I.T.S
(A - 003) is approved for the degree
Master of Engineering with specialization of CAD/CAM
M (MECHANICAL) by Gujarat
Technological Universsity.
Date:
Place: Rajkot
Examiners Sign
n and Name
N
( ) ( )
iii
iv
UNDERTAKING ABOUT ORIGINALITY OF WORK
We hereby certify that we are the sole authors of this thesis and that neither any part of this
thesis nor the whole of the thesis has been submitted for a degree to any other University or
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published or otherwise, are fully acknowledged
acknowledged in accordance with the standard
referencing practices. Furthermore, to the extent that we have included copyrighted
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Thesis review committee.
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we are sole responsible for the same and we understand that as per UGC norms, University
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Date:
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ACKNOWLEDGEMENT
This thesis work would not have been possible without the kind support of many
people. I take this opportunity to acknowledge that who has been great sense of support
and inspiration thought the thesis work successful.
There are lots of people who inspired me and helped, worked for me in every
possible way to provide the details about various related topics thus making thesis and
report work success.
My first gratitude goes to Prof. P. S. Puranik, Head of Department of
Mechanical Engineering for his guidance, encouragement and support during my
semester. Despite his busy schedule, he is always available to give me advice, support
and guidance during the entire period of my semester.
I am very grateful to my guide Ravi C. Patel, Assistant Professor Department of
Mechanical Engineering for all his diligence, guidance, encouragement and help
throughout the period of thesis, which have enabled me to complete the thesis work in
time. I also thank him for the time that he spared for me, from his extreme busy schedule.
His insight and creative ideas are always the inspiration for me during the thesis
I am also grateful to Mr. Brijesh Garala, Owner – Industrial Automation
Service, Rajkot. For his constant inspiration and encouragement along with his valuable
guidance has been instrumental in the successful completion of this project. He has
always been willingly present whenever i needed the slightest support from him.
I would like to express my sincere thanks to all my colleagues and the members
of the cloud computing thesis group. I would like to thank my parents for their valuable
support and encouragement.
Last, but not the least my special thanks goes to our institute, Atmiya Institute of
Technology & Science, for giving me this opportunity to work in the great environment.
Vikram Jayantilal Panchal
Atmiya Institute of Technology & Science, Rajkot
vi
TABLE OF CONTENTS
Title page
Certificate i
Compliance Certificate ii
Paper Publication Certificate iii
Thesis Approval Certificate iii
Industry Certificate iv
Declaration of Originality v
Acknowledgement vi
Table of contents vii
List of Figures x
List of Tables xiii
List of Graph xiv
Nomenclature xv
Abstract xvi
Chapter 1 Introduction 1-31
1.1 What is Rotary Table? 1
1.2 to 1.3 Types of Rotary Table 1-5
1.4 What is Cam? 5
1.4 Types Of Cam 5-11
1.5 Follower 12
1.5 to 1.6 Types Of Follower 12-17
1.7 Curves For Cam Design 18
1.7.1 Simple Polynomial Curve 18
1.7.2 Trigonometric Curve 18
1.8 Modified Cam Motion Curves 18
1.8.1 Modified Trapezoidal Curve 20
1.8.2 Modified Sine Curve 26
1.9 Servo Motor and its types 29-30
1.10 Bearing 30
1.11 Spur Gear Box 31
vii
Chapter 2 Literature Survey 32-38
Chapter 3 Problem Definition 39
Chapter 4 Methodology 40-49
4.1 Cylindrical Cam Design Calculation 40-43
4.2 Other Mathematical Calculation and Displacement,
Velocity , Acceleration and jerk Graph 44-49
Chapter 5 Modeling 50-59
5.1 2-D Drawing Of Indexng Plate 50
5.2 3-D Model Of Indexng Plate 50
5.3 2-D Drawing Of Cylindrical Cam 51
5.4 3-D Model Of Cylindrical Cam 51
5.5 2-D Drawing Of Roller 52
5.6 3-D Model Of Roller 52
5.7 2-D Drawing Of Follower 53
5.8 3-D Model Of Follower 53
5.9 2-D Drawing Of Flange 54
5.10 3-D Model Of Flange 54
5.11 2-D Drawing Of Key 55
5.12 3-D Model Of Key 55
5.13 2-D Drawing Of Shaft 56
5.14 3-D Model Of Shaft 56
5.15 2-D Drawing Of Housing 57
5.16 3-D Model Of Housing 57
5.17 3-D Model Of Rotary Indexing Table 58
Assembly In Different View
5.18 Explode View Of Rotary Indexing Table 58
Assembly
5.19 3-D Model Of Full Assembly Of Rotary 59
Indexing
Chapter 6 Result and Conclusions 60-62
viii
Scope of Future Work 62
References 63-64
Appendix
ix
LIST OF FIGURES
FIG. NO. TITLE PAGE NO.
1.1 Horizontal Rotary Table 1

1.2 Vertical Rotary Table 2
1.3 Tilting Rotary Table 2
1.4 Pneumatic Operated Rotary Table 3
1.5 Worm Gear And Worm Wheel Based Rotary 4
Table
1.6 Wedge Cam 6
1.7 Cylindrical Cam With Oscillating Follower 7
1.8 Cylindrical Cam With Indexing Turret 7
Tapered Follower
1.9 Globoidal Cam 8
1.10 Spherical Cam 9
1.11 Inverse Cam 9
1.12 Disk Cam 10
1.13 Rotating Cam 11
1.14 Translating Cam 11
1.15 Stationary Cam 11
1.16 Roller Follower 12
1.17 Knife-Edge Follower 13
1.18 Flat Face Follower 13
1.19 Spherical Face Follower 14
1.20 Gravity Constraint Follower 14
1.21 Spring Constraint Follower 14
1.22 Positive Constraint Follower 15
1.23 Translating Follower 15
1.24 Swinging Arm Follower 15
1.25 On Center Follower 16
1.26 Offset Follower 16
1.27 Dwell Rise Dwell Cam (D-R-D) 17
x
LIST OF FIGURES
FIG. NO. TITLE PAGE NO.
1.28 Dwell Rise Return Dwell Cam 17

1.29 Rise Return Rise Cam (R-R-R) 17
1.30 Modified Trapezoidal Curve 20
1.31 Modified Sine Wave Curve 26
4.1 Single roller cam design 40
5.1 2-D Drawing Of Indexng Plate 48
5.2 3-D Model Of Indexng Plate 48
5.3 2-D Drawing Of Cylindrical Cam 49
5.4 3-D Model Of Cylindrical Cam 49
5.5 2-D Drawing Of Roller 50
5.6 3-D Model Of Roller 50
5.7 2-D Drawing Of Follower 51
5.8 3-D Model Of Follower 51
5.9 2-D Drawing Of Flange 52
5.10 3-D Model Of Flange 52
5.11 2-D Drawing Of Key 53
5.12 3-D Model Of Key 53
5.13 2-D Drawing Of Shaft 54
5.14 3-D Model Of Shaft 54
5.15 2-D Drawing Of Housing 55
5.16 3-D Model Of Housing 55
5.17 3-D Model Of Rotary Indexing Table 56
Assembly In Different View
5.18 Explode View Of Rotary Indexing Table 56
5.19 3-D Model Of Full Assembly 57
6.1 Meshing Of Rotary Table Housing 60
6.2 Fixed Support Of The Rotary Table 60
6.3 Static Structural Loading Condition 61
6.4 Equivalent Stress Generated in Housing 61
6.5 Total Deformation Of Housing 62
xi
LIST OF TABLES
FIG NO TITLE PAGE.NO

2.1 Input data for Different cases 34
2.2 Result of three Motion curves 34
xii
LIST OF GRAPH
FIG.NO TITLE PAGE.NO
2.1 Modified Sine Curve 35
2.2 Modified Trapezoidal Curve 35
2.3 Modified Constant Velocity Curve 36
4.1 Displacement 47
4.2 Velocity 48
4.3 Acceleration 48
4.4 Jerk 49
Xiii
NOMENCLATURE
2-D 2-Dimensions
3-D 3-Dimensions
F No. of Follower
S No. Of indexing stations
Φ Angular displacement of follower (deg.)
c Center distance = dial to cam shaft
r Radius = dial center to follower center
y Linear displacement of follower from origin at any point of curve
(inch)
y' Linear displacement of follower from origin at any point of curve
(inch)
h offset of follower from dial center at origin of Primary curve (inch)
g offset of follower from dial center to at origin of primary and
secondary curve
d distance – Primary curve origin to secondary curve origin (inch)
K displacement factor
β total angular displacement of cam (deg.)
α Angular offset of follower from dial center (deg.)
Dd Indexing Plate Diameter
Wd Indexing Plate weight
Rs Radius to Station Center
Ws Weight of Single Station
t1 Dwell time
t2 Index time
Ti Inertia Torque
Tc Cam shaft Torque
Cv Constant Velocity Factor for Modified Sine Curve
Ca Constant Acceleration Factor for Modified Sine Curve
N Speed ( Revolution Per Minute)
xiv
APPENDIX
COMPLIANCE REPORT
A. COMMENTS FOR LITERATURE REVIEW (730002) SEM-3rd
The Literature Review which was conducted by the internal panel on
12.11.2013.They gave the comments which are as following.
COMMENTS
• collect more research papers
• selection of mechanism for project
• collect design data from industry
MODIFICATION
Based on the comments given by the internal panel, I have done modification
based on comments which are as following.
• 10 more research paper reviewed.
• Based on accuracy cylindrical cam with roller follower mechanism
selected for project.
• data collected from industry.
B. COMMENTS FOR DISSETATION PHASE-I (730003) SEM-3rd

The dissertation phase-1 which was conducted by the external examiners
panel on
05.12.2013. They gave the comments which are as following.
COMMENTS
• Decide the stages of rotary indexing table.
• Criteria for design and analysis should be clear which is under plan.
MODIFICATION
• Decided the stages of Rotary indexing table.
• Criteria for Design and Analysis cleared that to increase the Accuracy
and Reduce manufacturing cost
C. COMMENTS OF MID SEMESTER THESIS PROGRESS
REVIEW (740001)-SEM-4th
The mid semester thesis progress review which was conducted by the external
examiners panel on 28.04.2014.They gave the comments which are as following.
COMMENTS
• Use proper mathematical equation for design of whole assembly.
• Dynamic analysis result validate with help of standard literature or
experimentally.
MODIFICATION
• Proper mathematical equation used for design of whole assembly.
• Structural analysis is done.
CHAPTER 1
INTRODUCTION
1.1 Rotary Indexing Table

Rotary Table is important part to enhance the productivity of machining center
by reducing the machining setup. It’s a work holding device on a machining
center which is used to position the components in any desired position to
carry out the machining on different faces of component.[14]
Rotary Indexing Table are used to index Parts and Components in defined,
angular increments so that they can be machined, worked or assembled in
multiple operation. [14]
Rotary Tables have either fixed or adjustable indexing angles. During each
revolution, the Table stops for specified period time so that any operation can
be performed at each station. [14]
Types of Rotary Indexing Table based on Axis Movement
(A) Horizontal Rotary Table
(B) Vertical Rotary Table
(C) Tilting Rotary Table
(A) Horizontal Rotary Table[14]
In this type the Rotary table is placed horizontally.
It is rotates about single Vertical axis in the machining center.
Fig. : 1.1 Horizontal Rotary Table
Design and Analysis of Cylindrical Cam with Roller Follower Rotary Indexing Table
Page 1
CHAPTER 1
INTRODUCTION
(B) Vertical Rotary Table[14]

In this type the Rotary Table is placed vertically.
It is rotates about single horizontal axis in the machining center it is known
as Vertical Rotary Table.
Fig. 1.2 Vertical Rotary Table

(C) Tilting Rotary Table[14]
In this type the Rotary Table its rotates about two axis horizontal and
vertical in machining center it is known as Tilting Rotary Table.
Fig. 1.3 Tilting Rotary Table
Page 2
CHAPTER 1
INTRODUCTION
1.2 Rotary Table Based on Operating Mechanism[14]

Rotary tables are powered by pneumatic and electric motors, hydraulic drives
and manual actuation. Drive mechanism can be located above, below, behind
or to side of the table of the surface. Pneumatic rotary table are suitable for
small and medium loads. They are powered by pneumatic cylinders, each of
which represent index. Electrically powered table are generally faster than
pneumatic devices and handle heavier loads.
Tables are powered by hydraulic drives used pressurized fluid that transfers
rotational kinematic energy. Manual operated rotary tables often include table
hand crank or loosened, turned and adjusted by hand. For the large sized tables
drive motor in combination with reduction gear box and reduction pinion
gearing.
1.2.1 Pneumatic Operated Rotary Table[14]
This type of rotary table are operated by air with its pneumatic cylinders and
solenoid valves. When indexing happen proximity switch detects the angle
and position the parts.
Fig. 1.4 Pneumatic Operated Rotary Table
Page 3
CHAPTER 1
INTRODUCTION
1.2.2 Worm gear and Worm Wheel based Rotary Table[14]

This type of rotary table are operated by worm wheel and worm gear attached
with motors for indexing. this type of rotary table are widely used in the
machining center like CNC,VMC for indexing. This type of Rotary Table are
used for heavy duty parts or components for indexing.
Fig. 1.5 Worm gear and Worm Wheel based Rotary Table
1.3 Cam based Rotary Indexing Table[9]

Cam-driven mechanisms require little or no maintenance and are capable of
moving, with precision, a wide variety of products and components. Different
types of cams are used for indexing mechanism like cylindrical cam
,Globoidal cam etc which are operated by different motors like electric brake
motor, servo motor, special type of motor.
For example – larger Index Drives rotate several tons of automotive body parts
in seconds –and smaller index drives accurately index pharmaceutical
components and electronic components in milliseconds. The mechanical
technology typically requires no maintenance, other than routine checks for
proper lubrication. Rolling pre-loaded contact between the cams and cam
followers minimize wear and thermal efficiencies.
Page 4
CHAPTER 1
INTRODUCTION
Cam-Operated Indexing Systems have the Following Features and

Benefits[9]:
Controlled Acceleration and Decelerations
Repeatable, Accurate Positioning
High Load Capacity
High Speed Capability
Smooth Motion
Quick Settling Time in the Dwell Position
Low Maintenance, Superior Life
1.4 Cam[8]
A cam is mechanical part which imparts a prescribed motion to another by
direct contact. It may be stationary, translate or rotate. A cam is an element of
the cam-follower mechanical system that compels the movement of the
follower .
Cams are classified in three ways:
(A) In terms of their shape, such as wedge, radial, cylindrical, globoidal,
conical, spherical, or three-dimensional
(B) In terms of the follower motion, such as dwell-rise-dwell (DRD), dwell-
rise-return dwell (DRRD), or rise-return-rise (RRR)
(C) In terms of the follower constraint, which is accomplished by either
. positive drive or spring load as mentioned previously.
1.4(A) Based on Cam Shape Classification[8] :
1. Wedge Cam 4. Spherical Cam

2. Cylindrical Cam 5. Inverse Cam
3. Globoidal Cam 6. Radial Cam
Page 5
CHAPTER 1
INTRODUCTION
1.4(A).1 Wedge Cam[8]

The translating, wedge, or flat-plate cam is one that moves back and forth
driving a follower. The follower may either translate or oscillate, with its
position established by the cam shape and location. This is the simplest of all
cams. The follower is held in contact by a spring or a positive-drive groove
and roller. Translating cams have been built as large as 15 feet long for turning
the outside profile on gun barrels for milling and profiling work.
Fig 1.6 Wedge Cam
1.4(A).2 Cylindrical Cam[8]

The Cylindrical, barrel, or drum cam has a cylindrical shape that rotates about
its axis, and the follower translates or oscillates. Cylindrical cams usually use
cylindrical roller followers. Sometimes preloaded tapered conical rollers are
applied to reduce the slippage and wear caused by the different driving radii
and speeds. In addition, the cylindrical cam has been employed internally as
well as externally. Also, in rare cases, the cylinder may operates an “end” cam
on its end surface.
There are two types of cylindrical cams.
The first type has a circumferential contour cut in its surface. Below Figure
shows this kind of cylindrical cam driving an oscillating roller follower
Page 6
CHAPTER 1
INTRODUCTION
.
Fig. 1.7 cylindrical cam with oscillating follower
The second kind has a blade (blade cam) or thread projecting from its surface.
The cylindrical blade cam in has two designs, the first type to drive a
translating or oscillating follower (Fig. a) and the second type to index the
intermittent action of a turret through its start–stop cycle (Fig. b), which
indicates an indexing tapered roller turret.
Fig 1.8 cylindrical cam with indexing turret tapered follower
Page 7
CHAPTER 1
INTRODUCTION
1.4(A).3 Globoidal Cam[8]

The globoidal cam rotates about its axis driving a roller follower. It is similar
in appearance and action to the cylindrical cam. The globoidal cam shape is
determined by the arcs of an oscillating or indexing follower. There are two
types of globoidal cams.
The first kind has a groove with a circumferential contour cut in its surface for
an oscillating roller follower. This type of globoidal cam is either convex (Fig.
a), or concave (Fig. b). These cams are applied for small angles of follower
oscillation.
The second type of globoidal cam has a twisting “blade” or thread projecting
from its surface. This blade cam is called the roller gear drive or Ferguson
drive and has a roller follower on each side of the threads. The follower may
oscillate or have intermittent rotation. (Figure a )shows a single-thread type
with a globoidal body and an oscillating follower. (Figure b) is an indexing
globoidal cam with a turret follower. These blade-type globoidal indexing
cams have high accuracy, long life, low vibration, low noise, and sockless
performance under high speeds. For best action, the bearings should be
preloaded so that the system has limited backlash. This cam and the follower
can be obtained commercially. For indexing, they are often substituted for the
familiar Geneva and star-wheel mechanisms, which have inherently poor high-
speed dynamic properties.
Fig. 1.9 Globoidal Cam
Page 8
CHAPTER 1
INTRODUCTION
1.4(A).4 Spherical Cam[8]

The spherical cam ( Below Fig) has a rotating portion of a sphere, which
oscillates a follower having its axis perpendicular to the cam axis. This cam
represents the limiting case of a conical cam. The realms and restrictions of
the spherical cam are similar to that of the conical cam.
Fig. 1.10 Spherical Cam

1.4(A).5 Inverse cam[8]
The inverse cam is one in which the element corresponding to the follower of
a cam mechanism is utilized as the driver. Below Figure shows this cam
mechanism with an oscillating roller driving a translating follower having a
curved face. If the profile were a straight path perpendicular to the direction of
follower motion, the familiar inverse cam mechanism where the roller crank
and the cam both complete a full rotation in each revolution having dwell
action and intermittent motion.
Fig. 1.11 Inverse cam
Page 9
CHAPTER 1
INTRODUCTION
1.4(A).6 Disk Cam[8]

The radial, disk, or plate cam is one in which the position of the follower is
determined by radial distances from the cam axis. Below Figure shows a
radial open groove cam with oscillating roller follower used on a hosiery-
making machine.
The radial cam is by far the most popular because of its simplicity and
compactness. The conjugate, complementary, or double-disk cam is one
having dual radial disks, each in contact with a roller on the follower. Below
Figure shows this type with an oscillating follower. Roller followers are
generally used in this type of cam for optimum performance. The use of two
followers allows one roller to be preloaded against the other to eliminate the
backlash. This design effectively constrains the follower under high speed and
high dynamic loads resulting in lower noise, vibration, and wear.
Fig. 1.12 Disk Cam
1.4(B) Based on Cam Motion Classification[8]

1.Rotating cam
2.Translating cam
3.Stationary cam
Page 10
CHAPTER 1
INTRODUCTION
1.4(B).1 Rotating cam[8]

In this type the Cam Rotation is usually of constant speed and follower follow
the path of Cam .
Fig. 1.13 Rotating cam

[8]
1.4(B).2 Translating cam
The cam usually reciprocates in straight line motion and follower follow the
path of Cam
Fig. 1.14 Translating cam

1.4(B).3 Stationary cam[8]
The follower system rotates or translates and the Cam is Stationary.
Fig. 1.15 Stationary cam
Page 11
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INTRODUCTION
1.5 Follower[8]
The follower is the element directly contacting the cam .It may be of various
shapes.
The follower system includes all the elements to which the motion imparted
by the Cam. They may be directly connected to the follower, or through
linkage and gearing.
The follower and follower system may translate or oscillate. The drive consists
of the prime mover, gears, cam shaft, etc, which imparts motion to a rotating
cam, or to the follower system of a stationary cam.
1.5(A) Based on Follower Shape Classification[8]
1.Roller follower
2.Knife-Edge follower
3.Flat face follower
4.Spherical face follower
1.5(A).1 Roller Follower[8]

The Roller Follower is the most popular design for accomplishing this
criterion. Commercially available roller followers use ball or needle bearings
supported by a stem. In Roller Follower pressure angle should be low to
prevent jamming.
The Roller Follower has a low coefficient of friction when compared to the
other followers and is most frequently used in production machinery and some
automotive engines.
Fig. 1.16 Roller Follower
Page 12
CHAPTER 1
INTRODUCTION
1.5(A).2 Knife-Edge Follower[8]

The knife-edge, or point, Follower is as the name implies, a sharp edge in
contact with the cam. Although simple in construction, this type of follower is
not practical because it results in excessive wear of the contact point.
Fig. 1.17 Knife-Edge Follower

1.5(A).3 Flat face follower[8]
In this type of Follower will not jam.
Deflection or misalignment can cause high surface stress.
Fig. 1.18 Flat face Follower

1.5(A).4 Spherical face Follower
The Spherical face of the follower has a large radius that compensates for
detrimental deflection or misalignment that may occur with the Spherical Face
Follower.
Page 13
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INTRODUCTION
Fig. 1.19 Spherical face Follower

1.5(B) Based on Follower Constraint Classification[8]
1.Gravity constraint
2.Spring constraint
3.Positive constraint
1.5(B).1 Gravity constraint[8]
Weight of Follower sufficient to maintain contact
Fig. 1.20 Gravity constraint follower

1.5(B).2 Spring constraint[8]
The spring must be strong enough to maintain contact
Fig. 1.21 Spring constraint follower
Page 14
CHAPTER 1
INTRODUCTION
1.5(B).3 Positive constraint[8]

The groove maintains positive action for Follower
Fig. 1.22 Positive constraint follower

1.5(C) Based on Follower Motion Classification[8]
1.Translating Follower
2.Swinging arm Follower
1.5(C).1 Translating Follower[8]
The follower moves in straight line when the Cam Rotates
Fig. 1.23 Translating Follower

1.5(C).2 Swinging Arm Follower[8]
The follower moves in a circular arc when the Cam Rotates
Fig. 1.24 Swinging Arm Follower
Page 15
CHAPTER 1
INTRODUCTION
1.5(D) Based on Follower Position Classification[8]

1.On center Follower
2.Offset Follower
1.5(D).1 On Center Follower[8]
The on center follower is one in which the axis of the Follower movement is
displaced from the cam center of rotation.
Fig. 1.25 On Center Follower

1.5(D).2 Offset Follower[8]
The offset follower is one in which the axis of the follower movement is
displaced from the cam center of rotation. Offsetting often improves action by
reducing force, stress, and also the cam’s size. The eccentricity should be in
the direction that improves force components tending to jam the translating
follower in its bearing guide.
Fig. 1.26 Offset Follower
Page 16
CHAPTER 1
INTRODUCTION
1.6 Sequence of Follower Operation[9]

1.6.1 Dwell Rise Dwell Cam(D-R-D)
Dwell-Rise-Dwell Cam (DRD). This cam type, Figure has a dwell followed
by a rise contour followed by a dwell period at the maximum displacement. It
also may have dwell-fall-dwell action, which is analyzed similarly. DRD cams
are utilized in cylindrical and globoidal cams indexing a rotating turret.
Fig. 1.27 Dwell Rise Dwell Cam(D-R-D)

1.6.2 Dwell Rise Return Dwell Cam(D-R-R-D)
There is no dwell between rise and return
A dwell-rise-return-dwell cam (DRRD) has the rise and return preceded and
followed by dwells. It has limited application in machinery.
Fig. 1.28 Dwell Rise Return Dwell Cam(D-R-R-D)

1.6.3 Rise Return Rise Cam(R-R-R)
There are no dwells
Fig. 1.29 Dwell Rise Return Dwell Cam(D-R-R-D)

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INTRODUCTION
1.7 Basic Curves For Cam Design[9]

Types of basic curves
1. Simple polynomial
(a) Constant Velocity
(b) Constant Acceleration
(c) Cubic Curves
2. Trigonometric Curve
(a) Harmonic Curve
(b) Cycloidal Curve
(c) Elliptical Curve
(d) Double harmonic Curve
1.7.1 Simple Polynomial Curve[9]

The displacement equations of simple polynomial curves are of the form
y = Cϴ2
where n = any number, C = a constant
In this polynomial family, we have the following popular curves with integer
powers: straight line, n = 1; parabolic or constant acceleration, n = 2; cubic or
constant jerk, n = 3.
1.7.2 Trigonometric Curve[9]

The curves of trigonometric form are: simple harmonic motion (SHM) or
crank curve, which has a cosine acceleration curve, cycloidal, which has sine
acceleration curve, double harmonic, and elliptical.
1.8 Modified Cam Motion Curves[9]

1. Modified Trapezoidal Curve
2. Modified Sine Curve
3. Modified Constant Velocity Curve
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INTRODUCTION
Symbols
h = total rise of the follower, in
h'= maximum rise of the follower segment, in
h = maximum follower displacement for full of half curve, in
t = time, sec.
y = follower displacement
y' = dy / d = follower velocity, dimensionless
y''= d2y / d 2
= follower acceleration, dimensionless
y''' = d3y / d 3
= follower jerk, dimensionless
= dy / dt = y ′ = follower velocity
= d2y / dt2 = y ′′ = follower acceleration
= d3y / dt3 = y ′′′ = follower jerk
A = follower acceleration, in / sec2
Vmax = maximum velocity, inch / sec
V0 = follower initial velocity, inch / sec
a = follower acceleration, dimensionless
= cam angle for rise h, radians
= angle for maximum follower displacement, radians
1, 2= periods during positive and negative accelerations respectively, rad
= cam angle rotations, radians
= cam speed, rad / sec
v0 = follower initial velocity, inch / radians

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INTRODUCTION
1.8.1 Modified Trapezoidal Curve[9]

A combination cam curve that has been used in lieu of the trapezoidal acceleration
curve is the modified trapezoidal curve. It is composed of a parabolic motion
combined with the cycloidal curve. This combination reduces the maximum
acceleration set the expense of somewhat higher jerk values.
The modified trapezoidal curve is popular in industry. However, it has one
objectionable Characteristic that torque goes from positive maximum to negative
maximum in 20 percent of the travel time.
If dynamic forces represent a significant part of the load on the cam, this sudden
release of energy may be detrimental to the cam-follower system performance and
limit the operating speeds.
Cycloidal curve from which the modified trapezoidal curve is developed. The
displacement and acceleration diagrams of the modified trapezoidal are shown
below Fig. The variables pertaining to the cycloidal curve are denoted by the
primed Symbols. At the start of the rise from A to B the follower acceleration is a
Quarter sine wave; from B to C the acceleration is constant; and from C to D the
acceleration decreases to zero with a quarter sine wave. After D, the follower has
negative acceleration in the same way that it was positively accelerated.
Fig. 1.30 Modified Trapezoidal Curve
In trapezoidal acceleration curve, we use b = 1 / 8 in the derivation. The equations

of the curve from A to B are
Displacement y = h' (2 / - 1/2π sin 4π / β),
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INTRODUCTION
Velocity y' = h' / (2 - 1/2 cos4π / β), (1.1)
Acceleration y''= 8πh' / 2

sin 4π / β,
where h'= maximum rise for cycloidal segment
when point B is reached = β / 8.Substituting the value of in equitation (1.1)

provides the characteristic equation at point B.
y1 = h'(1 / 4 - 1 / 2π)
y1' = 2 h'/
y1'' = 8πh'/ 2
.
The general expression for displacement under constant acceleration has a

displacement
2
y = v0 +a (1)
where = cam angle rotations, dimensionless
= follower acceleration, dimensionless
v0 = follower initial velocity, dimensionless
Therefore general equitation of the curve from B to C are
y = y1 + v0 ( - β / 8 ) + 1/2 a ( - β / 8)2
y' = v0 + a( - β / 8)
y'' = a
To get the displacement, velocity, acceleration to match at the junction B, it is

necessary that
v0 = 2 h' /
a = 8πh' / 2
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INTRODUCTION
Therefore, the equations from B to C are
y = h'(1/4 - 1 /2 π) + 2h'/ ( - β / 8) + 4πh' / 2

( - β / 8)2 (1.3)
y'= 2h' / + 8πh' / 2

( - β / 8)
y'' = 8πh' / 2
when point C is reached, = 3β / 8. substituting in Eq.(3.3) we obtain
y = 3 / 4h' - h' / 2π + πh' / 4
y2 = y - y1 = h' / 2 - πh' / 4
The cycloidal displacement is the sum of a constant velocity displacement and

quarter sine displacement. The displacement equation of the curve from C to is
y = y1 + y2 + C1 + C2 ( - 3β / 8 / β) + C3 sin(4π( - β / 2) / β)
Hence,
y' = C2 / + C3 4π / cos 4π( - β / 2) / β)
y'' = - C3 16 π2 / 2
sin 4π ( - β / 2) / β) (1.4)
where C1, C2 and C3 are undetermined coefficients that can be obtained as follows:
An acceleration match at point C (when = 3β / 8) requires
8πh'/ 2
= [-C3 16 π2 / 2
sin 4π( - β / 2) / β)]at =3β/8
thus giving
C3 = h' / 2π
A velocity match at point C requires
[2h'/ + 8πh'/ 2
( - β / 8)] =3β / 8
= [C2 / β + h' / 2π 4π / ( - β / 2 / β)] =3β / 8
from which we obtain
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INTRODUCTION
C2 = 2h'(1 + π)
the total displacement at point C is
y = y1 + y2
or equivalently
[C1 = (- 2h' (1 + π) ( - 3β / 8) / β - h' / 2π sin4π ( - β / 2) / β)] =3β / 8 =0
from which C1 can be obtained
C1 = h' / 2π
put the value of C1 , C2 , C3 in the displacement equation gives the curve from C to
D
y = (h' / 4 - h' / 2π) + (h' / 2 + πh' / 4) + h' / 2π + 2h'(1 + π)( - 3β / 8) /β - h' / 2π sin
4π( - β /4 ) / β) or
y = [h'(- π / 2 + 2(1 + π) / β - sin4π( - β / 4) / β)] (1.5)
At point D (i.e. when =β/2) the total displacement can be found from this
equation to be
y = h'(1 + π / 2)
the displacement of the final segment is
y = y1 - y2 - y3
or y3 = h'(1 / 4 + π / 4 +1 / 2π)
from the relationship
y1 + y2 + y3 = h / 2
establishing the relationship between h' and h
h' = h / 2 + π (1.6)
so the displacement equation of first three segments are
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y = h / 2 + π(2 / β - 1 / 2 π sin 4π / β)
{0 ≤ ≤ β / 8} (1.7)
y = h / 2 + π(1 / 4 - 1 / 2π + 2 / β ( - β / 8)2
{β / 8 ≤ ≤ 3β / 8}
y = h / 2 + π ( -π / 2 + 2 (1 + π) / β + 1 / 2 π sin4π( - β/ 2 / β)
{3β / 8 ≤ ≤ β / 2}
evaluating all the constants , characteristic curve equation are
for 0 ≤ ≤β/8 (1.8)
y = 0.09724613h (4 / β - 1 / π sin 4 π / β)
y' = 0.3889845 ℎ / β (1 - cos4 π / β)
y'' = 4.888124 ℎ / β2 sin4 π /β
y''' = 61.425975 ℎ / β3 cos4 π /β
for β / 8 ≤ ≤ 3β / 8,
2
y = h(2.44401188 / β - 0.22203094 / β + 0.00723406)
y' = ℎ / β (4.888124 / β - 0.222031)
y'' = ℎ / β2 (4.88124)
y''' = 0
for 3β / 8 ≤ ≤β/2
y = h(1.6110155 / β - 0.0309544 sin(4π / β ) - 0.3055077)
y' = ℎ / β(1.6110155 - 0.3889845 cos (4π / β)
y'' = ℎ / β2( 4.888124sin4 π / β)
y''' = -61.425975 ℎ / β3cos4 π /β

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for 1 / 2 ≤ /β≤5/8
y = h(1.6110155 / β - 0.0309544 sin4π / β) - 0.3055077)
y' = ℎ / β(1.6110155 - 0.3889845 cos4π / β)
y'' = ℎ / β2(4.888124 sin4 π / β)
y''' = -61.425975 ℎ / β3 cos4 π /β
for 5 / 8 ≤ /β≤7/8
y = h(4.6660917 / β - 2.44406188 sin( / β )2 - 1.2292650)
y' = ℎ / β (4.6660928- 4.888124 / β)
y'' = ℎ / β2 (- 4.888124)
y''' = 0
for 7 / 8 ≤ /β≤1
y = h (0.6110155 - 0.3889845 / β - 0.0309544 sin(4π /β))
y' = ℎ / β (0.3889845 - 0.3889845 cos (4π /β))
y'' = ℎ / β2 (- 4.888124 sin4 π / β)
y''' = 61.425975 ℎ / β3 cos4 π /β
A computer solution is employed to establish the incremental displacement value

and the characteristic curves of the action.
The modified trapezoidal curve has the following peak values
y' = 2h / β
y'' = 4.888 h / β2
y''' = 61.43 h / β3 (1.9)
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INTRODUCTION
1.8.2 Modified Sine Wave Curve[9]

The modified sine curve is a combination of quarter sine wave curves. In
terms of Its torsional action, the change from positive to negative torque
occurs in over 40 percent of the travel time.
This attribute makes this curve attractive as a choice in moving large masses
such as indexing intermittent turrets. Its lower torque and power demand make
the modified sine curve one of the best choices of curves.
Figure shows the basic cycloid curve, from which the combination curve is
developed also shows the displacement and the acceleration diagram of the
modified sine curve.
The primed symbols used in the drawing refer to the basic cycloidal curve.
One-half of the rises is divided into the following segments the follower is
accelerated A TO B (from = 0 to = )
From A to B with a quarter sine wave and the acceleration decrease to zero
from B to C( from = to = ) again with a quarter sine wave. The
equations of cycloidal motion from A to B, given that β / 8 is the length of the

initial quarter Sine wave are
Displacement y = h' (2 / - 1 / 2π sin 4π / β)
Velocity y' = h' / (2 - 2 cos4π / β)
Acceleration y'' = 8πh' / 2
sin 4π /β,
Fig. 1.31 Modified Sine Wave Curve
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INTRODUCTION
y1 = h'(1 / 4 - 1 / 2π)
y1' = 2 h' / (2.1)
y1'' = 8πh' / 2
The sine curve from B to C characteristics are :
y = y1 + y2 + C1 + C2 ( - β / 8 / β) + C3 sin(4π / 3 β + π / 3)
y' = C2 / + C3 4π / 3 cos (4π / 3β + π / 3)) (2.2)
y'' = - C3 16 π2 / 9 2
sin (4π / 3β + π / 3))
The acceleration boundary condition give :
8πh'/ 2
= [-C3 16 π2 / 9 2
sin 4π / 3β + π / 3)]at =β/8
C3 = - 9h' / 2 π
2h' / = (C2 / - 9h' / 2π(4π / 3β) cos 4π / 3β + π / 3) =β/8
C2 = 2h'
The displacement boundary condition give :
[C1 + 2h' ( - β / 8) / β) - 9h' / 2π sin(4π / 3β + π / 3] = 0
C1 = 9h' / 2π
then
y = (h' / 4 - h' / 2π) + 9h' / 2π + ( - β / 8) / β)
- 9h' / 2π sin (4π / 3β + π / 3) (2.3)
= h' (4 / π + 2 / β - 9 / 2π sin( 4π / 3 β + π / 3) )
when = β / 2 , the rise is
y = h' (1 + 4 / π) hence
y2 = y - y1 = (3 / 4 + 9 / 2π )h'.
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INTRODUCTION
finally from the relationship
y = y1 + y2 = h / 2
we obtain h' = πh / 2(π + 4 ).
therefore ,the displacement equations of the modified sine curve are
y = h(π / 2 (π + 4) / β - 1 / 4(π + 4 ) sin (4 π / β))
0≤ ≤β/8
y = h(2/(π + 4) + π/2(π + 4) /β - 9 / (π + 4)sin(4π / 3β + π / 3)
β/8≤ ≤ 7 / 8 β (2.4)
y = h(4 / (π + 4 ) + π / (π + 4 ) / β - 1 / 4(π + 4 ) sin( 4π /β)
7β / 8 ≤ ≤β
evaluating all constants the characteristics equation for modified sine curve are :
for 0 ≤ ≤β/8
y = h ( 0.43990 / β - 0.35014 sin 4π / β
y'= 0.43990 ℎ / β ( 1 - cos4π / β)
y''= 5.52796 ℎ / β2sin4 π /β
y''' = 69.4664 ℎ / β3 cos4 π /β
for β / 8 ≤ ≤ 7 / 8β
y = h (0.28005 + 0.43990 / β - 0.351506 cos (4π / β - π / 3))
y' = h / β ( 0.43990 + 1.31970 sin (4 π / β + π / 3 ))
y'' = 5.52796 ℎ / β2 sin(4 π / β + π / 3)
y''' = 23.1555 ℎ / β3 cos4 π / β + π / 4)
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for 7 / 8 ≤ /β≤1
y = h ( 0.56010 + 0.43990 / β - 0.03515006 sin(4 π / β ))
y' = h / β ( 0.43989 ( 1- cos 4 π / β )) (2.5)
y'' = 5.52796 ℎ / β2sin(4 π /β)
y''' = 69.4664 ℎ / β3 cos4 π /β
A computer solution is employed to establish the incremental displacement values

and the characteristic curve of the action.
The maximum velocity of the modified sine curve is y'max = 1.760 h / β
maximum acceleration is y''max = 5.58 ℎ / β2
and the maximum jerk is y'''max= 69.4664 ℎ / β3
1.9 Servo Motor

A Servomotor is a rotary actuator that allows for precise control of angular
position, velocity and acceleration. It consists of a suitable motor coupled to a
sensor for position feedback. It also requires a relatively sophisticated
controller, often a dedicated module designed specifically for use with
Servomotors.
Servomotors are not a different class of motor, on the basis of fundamental
operating principle, but uses servomechanism to achieve closed loop control
with a generic open loop motor.
Servomotors are used in applications such as robotics, CNC machinery or
automated manufacturing.
In a closed-loop Servomechanism that uses position feedback to control its
motion and final position. The input to its control is some signal, either
analogue or digital, representing the position commanded for the output shaft.
The motor is paired with some type of encoder to provide position and speed
feedback. In the simplest case, only the position is measured. The measured
position of the output is compared to the command position, the external input
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INTRODUCTION
to the controller. If the output position differs from that required, an error
signal is generated which then causes the motor to rotate in either direction, as
needed to bring the output shaft to the appropriate position. As the positions
approach, the error signal reduces to zero and the motor stops.
The very simplest servomotors use position-only sensing via a potentiometer
and bang-bang control of their motor; the motor always rotates at full speed
(or is stopped). This type of servomotor is not widely used in industrial motion
control, but they form the basis of the simple and cheap servos used for radio-
controlled models.
More sophisticated servomotors measure both the position and also the speed
of the output shaft. They may also control the speed of their motor, rather than
always running at full speed. Both of these enhancements, usually in
combination with a PID control algorithm, allow the servomotor to be brought
to its commanded position more quickly and more precisely, with less
overshooting.
1.9.1 Types of Servo Motors
Ac Servo Motor
Ac Servo can handle higher current surges and tend to be used in industrial
Machinery.
Dc Servo Motor
Dc Servos are not designed for high current surges and are usually better
suited for smaller applications. Dc Motors are less expensive than their ac
components.
Servo Motors that have been built specifically for continuous rotation, making
It an easy way to get your robot moving. They feature two ball bearings on the
output shaft for reduced friction and easy access to the rest-point adjustment
Potentiometer.
1.10 Bearing
Bearing is a machine element that constrains relative motion and reduces
friction between moving parts to only the desired motion
A needle roller bearing is a bearing which uses small rollers. The difference of
a needle roller bearing and roller bearing is the ratio of diameter and length of
Page 30
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INTRODUCTION
their rollers, when the ratio of the diameter and the length of roller of a roller
bearing is between the interval of 0.4 to 0.1, that roller bearing is called as
needle roller bearing. They are used to reduce friction of a rotating surface.
Features
great load carrying capacity
compact design
low internal forces
high rigidity
good load carrying capacity
1.11 Spur Gear Box
It is most common type of gearbox. Spur gears are straight cut gears
intermeshed together to form the gearbox. They consist of a cylinder or disk
with the teeth projecting radially, and although they are not straight-sided in
form, the edge of each tooth is straight and aligned parallel to the axis of
rotation. These gears can be meshed together correctly only if they are fitted to
parallel shafts.
They have straight teeth that mesh with other spur gears to reduce speed and
increase torque or increase speed and decrease torque or change rotational
direction. Generally it takes many spur gears to make large reductions and
space is always a limiting factor when designing these.If you were to drive the
large spur gear, the smaller one would revolve much faster meaning that there
would be a torque reduction and a speed increase on the other spur gear. If you
ran the smaller spur gear there would be less speed transferring to the bigger
spur gear but the torque would be greater.
Advantages
Cheap to manufacture
high power transmission efficiency.
compact and easy to install.
offer constant velocity ratio.
highly reliable.
transmit large amount of power (of the order of 50,000 kW).
Page 31
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LITERATURE REVIEW
Research Papers
B.Santhosh Kumar, N.Chandrashekhar Reddy,” Design and analysis of
CNC Rotary Table for Horizontal Machining Center”, International
Journal of Research in Engineering & Advance Technology, Volume 1,
Issue 4, Aug-Sep 2013[1]
In this paper Author had discussed about the CNC rotary table having sized
500*500 mm to be designed to support and hold the work piece and its weight
8000N and its positional accuracy +-10 and its rotational speed 30 rpm.
Design of CNC Rotary Table
(1) Machining force - 1020 N considered
(2) Design of worm and worm wheel for rotary table
(3) Angle encoder /positioning system with servo motor had taken RCN and
RPN angle encoder used for excellent dynamic performance with integrated
stator coupling.
ERN 200 series with system accuracy +-10 sec and having step o.oo1 and
speed limit 30 rpm
(4) Selection of locknut had taken based on tightening torque.
Based on proposed design developed rotary table was driven by duplex worm
gear gearing based mechanism which greatly reduced the speed and desired
speed easily achieved and its indexing step is 0.001degree and its positional
accuracy its maintained by angle encoder ERA 200 series and servo motor.
Two four point angular contact ball bearing was used at top and bottom to
support the table for higher rigidity it maintained during Machining
operations.
Worm shaft at both sides was supported by taper roller bearing which takes
the combined loads while rotation of clockwise and anticlockwise maintains
higher rigidity.
Comparison between solid pallet and static and modal of ribbing pattern pallet
by FEA the ribs pattern pallet had less weight and 4.7 micron deflection and
its safe under 10 micron deflection. Developed weldment housing using
structural steel plates had less cost and no cost of mould and Machining.
Page 32
CHAPTER 2
LITERATURE REVIEW
Marian Funaru, Gheorghe Stan, Lucian Mihaila, Marius Pascu, Dragos

Andrioaia, “Precise Rotary Table Indexing system used on Milling
Machining Centers”, Journal of Engineering Studies and Research –
Volume 19 (2013) No. 1[2]
In this paper Author discussed about Indexing mechanism of precise rotary
table servo motor was attached with pulse encoder which monitors the
position and speed of machine tool table and clamping system was presented.
This Rotary Tables Indexing Mechanism had very good precision and also
high Repeatability by use of the precise curvic coupling in the mechanism and
maximum load capacity and which had minimum Indexing angle of one
degree.
In this Mechanism Table clamp and unclamp was driven by Hydraulically
operated Solenoid Valve with Proximity switch for quick and Accurate
position.
Suresh Sanap, Ketan Jagtap and Keshav Nandukar, ”Design and
Analysis of Globoidal Cam Index Drive”, International Journal of
Scientific Research & Technology, Volume 2 Issue 3 pp 163-168 June
2013[3]
In this paper author discussed about the Globoidal cam mechanism. The
mechanism designed for to reduce the vibration and indexing motion was
smooth. In this mechanism cylindrical rollers which mounted at its turret with
globoidal cam used for angular indexing motion.
Author discussed on different motion curves for same input values of input
parameters, peak output torque and jerks were determined.
Based on Motion of the follower he had developed three motion curves which
was best for the angular indexing motion curve provide superior velocity,
acceleration based on input characteristic.
1) Modified Constant Velocity Curve
2) Modified Sine Curve
3) Modified Trapezoidal Curve
Page 33
CHAPTER 2
LITERATURE REVIEW
INPUT DATA FOR DIFFERENT CASES
Case
Sr No Data Symbol Unit Case I
II
Application Start Start
1 - -
type Stop stop
Cam Index
2 Degree 270 270
period
Weight of dial
3 Wd Kg 40 225
plate
Diameter of
4 D M 0.95 1.2
dial plate
Total Wt of
5 Ws Kg 35 200
work station
Radius of
6 Rs M 0.34 0.55
curvature
7 No of stations S - 4 4
8 Index time t2 Sec 1.61 2.87
TABLE 2.1
RESULTS FOR THREE MOTION CURVES
Modified Constant
Motion Curve Modified Sine Modified Trapezoidal
Velocity
/parameter MSV MTC
MCV
Data I Data II Data I Data II Data I Data II
Inertia I
8.559 101.00 8.559 101.00 8.559 101.0
Kg-m2
Angular
Acceleration 5.959 1.875 5.270 1.6585 8.632 2.71
2
rad/sec
Peak output
Torque 51.00 189.4 45.10 167.50 73.88 274.3
T Nm
Radius of gyration
0.3378 0.487 0.337 0.4875 0.337 0.4875
K
Input Torque i/p-
30.05 111.6 26.57 98.71 43.53 161.6
Nm
Input Power
0.234 0.488 0.207 0.4343 0.339 0.708
P i/p- hp
Maximum Jerk
1741.7 307.7 1540.1 272.13 5049.4 888.3
m/sec3
TABLE 2.2
Page 34
CHAPTER 2
LITERATURE REVIEW
For comparison applications of Case I and Case II globoidal cam indexing

mechanism produces controlled output acceleration /deceleration because its
output shaft is at all times tightly connected to its input shaft, making the
output rotation a strict function of the input Output torque and jerk are
minimum for MT curve for both applications. Time period 1 is assumed for
both the data in which index angle is 270 degree for input motion and 90
degree for output motion. From the centesimal scales prepared for Modified
Sine, Modified Trapezoid, Modified Constant Velocity motion curves graph of
cam angle and jerk values are obtained. The graphs obtained are shown in
GRAPH OF NON DIMENSIONLESS TIME VS JERK
GRAPH 2.1
GRAPH 2.2
Page 35
CHAPTER 2
LITERATURE REVIEW
GRAPH 2.3
Based on these input parameters analysis the motion curves and obtained the
results that for high loads and high speeds modified trapezoidal was best for
low load and high speed and modified sine was best and for high load and low
speeds constant velocity was best.
Based on mathematically analysis values of torque and Jerk are minimum and
input power required was low for Modified Sine curve was best for angular
Indexing for Globoidal Cam Index Drive.
Oh Yeon Taek,” Design of Precision Angular Indexing System for
Calibration of Rotary Tables”, Journal of Mechanical Science and
Technology 26(3) (2012)847-855[4]
In this Paper Author had Discussed that Developed a New Indexing Table
with 6 point contact Kinematic concept with ball and Vee groove plate with
Special Radial Cam type Indexing Table which lift up and Rotate.
Its Calibration of Angular Measurement was done by laser Interferometer with
Computer Hardware and Software with Motor Control Box.
It’s having Resolution of +- 10 based on laser interferometer which reduced
the angle error generated by other Indexing Table
It’s having good rigidity and Repeatability 0.1 micron. The Performance was
evaluated in both Horizontal and Vertical Direction.
Page 36
CHAPTER 2
LITERATURE REVIEW
Dan Cracian, Tiberiu Vesselenyi, Constantin Bungau, Macedom Ganea,

Traian Buidos, Florin Blaga, Iulian Stanase, “Design Solution for Rotary
Table for five axis Machining ”, Annalls of the Orada University Facile of
Management and Technology Engineering ,Issue # 1,May 2013[5]
In this paper author discussed about the Rotary Table in which its diameter is
250 mm, Maximum shaft Rotation 75 rotations per minute and Positive tilt
angle 135 degree and torque 420 nm and Negative tilt angle is 10 degree.
Based on Proposed Dimensions the Rotary Table its feed mechanism was
duplex worm gear with timing belt through the actuation of servo drive it was
suitable for five axis Machining.
In the feed mechanism the worm gear ratio 1:1 with Eccentric Tensioners was
used in the Rotary Table which Reduces the Backlash and Vibration with high
Accuracy and Repeatability.
Due to Large tilt Angle Large Sculptural Surfaces was easily achieved.
K.M.Mudhita Dassanayake, Masaomi Tsutsumi “High Performance
Rotary Table for Machine Tool Applications”, March 2009.[6]
High performance of the rotary table was immense necessary part of the multi
axis machines.
Globoidal cam with roller follower was gave zero backlash, higher stiffness
and less fluctuation than worm gear mechanism.
Based on proposed measured data results this mechanism gives higher the
positioning, accuracy, and very less effect on unbalanced mass.
The rotary table driven by servo motor with rotary encoder gave higher
accuracy than of Measurement
M.B.Vaghela, V.J.Savsani, S.B.Jadeja, “Design and Analysis of Radial
Cam and Globoidal Cam of Tool changing Mechanism used in VMC by
using DYNACAM ,International Journal on Mechanical Engineering and
Robotics, Issn 2321-5747,Volume 1,Issue 2, 2013[7]
In the paper discussed about the methodology of design and analysis of radial
cam and globoidal cam for tool changing mechanism of ATC which used in
VMC and gave accurate motion by using DYNACAM 10 software.
Page 37
CHAPTER 2
LITERATURE REVIEW
By using radial cam obtained results very close displacement at shaft of tool
changing mechanism, actual displacement is 115 mm and by using radial cam
obtain 114.95 mm displacement shaft.
To get exact 360 degree rotation of (270 clockwise and 90 anticlockwise) used
a globoidal cam in tool changing mechanism.
Design and analysis of radial and globoidal cam using DYNACAM software
was getting proper simultaneously two types of downward and upward and
rotary motion of tool changing mechanism of ATC and find the kinetostatic
force and toque, surface stress in cam follower and linkage design as per
motion of cam.
The Design of Cam with help of DYNACAM SOFTWARE used to prepare
Geometrics Drawing and Model of Cam which used to prepare Maximum and
Minimum Result of Displacement, Velocity, Acceleration and Jerk.
Page 38
CHAPTER 3
PROBLEM DEFINITION
Now a day's Machining of component within single setup is more important

concept for manufacturing of any product. As single set up machining results
dimensional and geometrical tolerance within specific limit, this concept with
specific product like Rotary Table, Indexing Table, work holding devices,
special jig and fixtures etc. with machining center is more predominate.
Single setup concept will increase productivity with cost effectiveness and
consistent accuracy. The Rotary Indexing Mechanism which is used for
getting angular motion in required time.
Different types of Indexing Mechanism are available in market like cylindrical
cam with roller follower, duplex worm gear based, and Geneva mechanism. In
Designing of Indexing Mechanism, cam and follower and its motion curve is
major part for creating its profile for getting particular Indexing with required
time, accuracy and cost.
At Present Machining Centers increased productivity, due to reduced auxiliary
time ,through concentrating higher number of operation needed for changing
work piece position and avoiding the removal, transport setting and alignment
of the work piece, which in many cases represents the source of many errors.
In Machining Center the Rotary Table is driven by worm gear and worm
wheel based Mechanism gives a less accuracy when it used for long time due
to backlash generation in gears.
In Industry require a good accuracy for position of work piece an due to above
error it cannot get the good position accuracy and this type of rotary tables
cost for replacement in machining center is high so due to remove this error
generated a new type indexing type of rotary table is require which gives
quick indexing and zero backlash which gives a good accuracy.
Page 39
CHAPTER 4
METHODOLOGY
4.1 Cylindrical Cam Design
F = No of Follower = 12, S = No of indexing stations =12
Φ =Angular displacement of follower (deg.)
c= center distance= dial to cam shaft = 95 mm = 3.74 inch
r = radius= dial center to follower center
y = linear displacement of follower from origin at any point of curve (inch)
y'= linear displacement of follower from origin at any point of curve (inch)
h = offset of follower from dial center at origin of Primary curve (inch)
g = offset of follower from dial center to at origin of primary secondary curve
d = distance – Primary curve origin to secondary curve origin (inch)
K = displacement factor
β = total angular displacement of cam (deg.)
α = angular offset of follower from dial center (deg.)
Φ N = 360/ S = 360/12= 30 deg.
r = c / cos Φ N = 3.74 / cos 0.5*30 = 0.124 inch
h = r sin 0.5 Φ N = 0.124 * sin 0.5*30 = 0.0324 inch
g = r sin 1.5 Φ N = 0.124 * sin 1.5*30 = 0.097 inch
d = c - r cos1.5 Φ N = 3.74 - 0.124 * cos 1.5 * 30 = 0.021 inch
fig 4.1 single roller cam design
Page 40
CHAPTER 4
METHODOLOGY
Φn= K * Φ N
n=0 0 * 30 = 0 deg.
n = 10 0.00634 * 30 = 0.19 deg.
n = 20 0.04310 * 30 = 1.293 deg.
n = 30 0.11718 * 30 = 3.5154 deg.
n = 40 0.22417 * 30 = 6.7251 deg.
n = 50 0.35558 * 30 = 10.674 deg.
n= 59 0.48 * 30 = 14.4 deg.
For Curve A-B (Φ n < 0.5 Φ N )
α n = 0.5 Φ N - Φ n
0.5*30 - 0 = 15 deg
0.5*30 - 0.19 = 14.81 deg
0.5*30 - 1.293 = 13.707 deg
0.5*30 - 3.514 = 11.486 deg
0.5* 30 - 6.7251 = 8.2749 deg
0.5* 30 - 10.674 = 4.326 deg
0.5* 30 - 14.4 = 0.6 deg
Page 41
CHAPTER 4
METHODOLOGY
y = h - r sin αn
0.0324 - 0.124 * sin 15 = 3.06 * 10-4 inch
0.0324 - 0.124 * sin 14.81 = 7.03 * 10-4 inch
0.0324 - 0.124 * sin 13.7 = 3.03 * 10-3 inch
0.0324 - 0.124 * sin 11.48 = 7.72* 10-3 inch
0.0324 - 0.124 * sin 8.27 = 0.014 inch
0.0324 - 0.124 * sin 4.3 = 0.023 inch
0.0324 - 0.124 * sin 0.6 = 0.031 inch
For Curve B - C (Φ n > 0.5 Φ N )
α n = Φ n - 0.5 Φ N
0 - 0.5 * 30 = -15deg
0.19 - 0.5 * 30 = -14.81 deg
1.29 - 0.5 * 30 = -13.71 deg
3.51 - 0.5 * 30 = -11.49 deg
6.7 - * 30 = -8.3 deg
10.6 - 0.5 * 30 = -4.4 deg
14.4- 0.5 * 30 = -0.6 deg
y = h + r sin αn
Page 42
CHAPTER 4
METHODOLOGY
0.0324 + 0.124 sin -15 = 3.06 *10-4 inch
0.0324 + 0.124 sin -14.81 = 7.03*10-4 inch
0.0324 + 0.124 sin -13.71 = 3.011*10-3 inch
0.0324 + 0.124 sin -11.49 = 7.69*10-3 inch
0.0324 + 0.124 sin -8.3 = 0.014 inch
0.0324 + 0.124 sin -4.4 = 0.022 inch
0.0324 + 0.124 sin -0.6 = 0.031 inch
For curve A'- B'
αn = 1.5 Φ N - Φ n
1.5* 30 - 0 = 45 deg
1.5* 30 - 0.19 =44.81 deg
1.5* 30 - 1.2 = 43.8 deg
1.5* 30 - 3.5 = 41.5deg
1.5* 30 - 6.7 = 38.3 deg
1.5* 30 - 10.6 =34.4 deg
1.5* 30 - 14.4 =30.6 deg
y’ = g - r sin αn
Page 43
CHAPTER 4
METHODOLOGY
0.097 - 0.124 sin 45 = 9.31*10-3 inch
0.097 - 0.124 sin 44.81 = 9.61*10-3 inch
0.097 - 0.124 sin 43.8 = 0.011 inch
0.097 - 0.124 sin 41.5=0.014 inch
0.097 - 0.124 sin 38.3 =0.020 inch
0.097 - 0.124 sin 34.4 =0.026 inch
0.097 - 0.124 sin 30.6 =0.033 inch
4.2 CALCULATION :
Indexing Plate Diameter(Dd) = 16.141 inch
Indexing Plate weight (Wd) = 342.21 lbs.
Radius to Station Center(Rs) = 4.724 inch
Weight of Single Station (Ws)= 10.78 lbs
No of Followers = 12
Dwell time (t1)= 1 second
Index time(t2) = 1 second
Index period (β) = 360 degree
Motor = 600 Rpm
Index rate :
β / t2 * 12
= 360 / 1 * 12
= 30 index/second
Inertia loading :
Dial plate Inertia :
Wd * D2 / 8
Page 44
CHAPTER 4
METHODOLOGY
= 342.21 * (16.141)2 / 8
= 11143 lb.inch2
Station Inertia :
WS * S * (RS)2
= 10.78 * 12 * (4.724)2
= 2886 lb- inch2
Total WK2 Inertia External :

WK2 (ext) = 11143+2886
= 14029 lb - inch2
Preliminary Output Torque :

Ti = 0.09 * S.F * WK2 (ext) / S * t22
= 0.09 * 1.3 * 14029/ 12 * 12
= 136.78 inch-lbs.
Inertia Torque :
Ti = 0.09 * S.F * (WK2 (ext) + WK2 (int)) / S * t22
= 0.09 * 1.3 * (14029 + 110 ) / 12 * 12
= 137.85 inch - lbs
Cam shaft Torque :

K f = C v * 360*M / β * S
= 1.7596 *360 *1 /360 * 12
= 0.141
K i = 0.56 * K f
= 0.56* 0.141
= 0.081
Page 45
CHAPTER 4
METHODOLOGY
T c = Ti * K i
= 137.81 * 0.081
= 11.16 inch - lbs
= 1.26 NM
Cam shaft Rpm :

β / t2 * 12 * M
= 360 / 1 * 12 * 1
= 30 RPM
Gear Ratio :
N motor / N camshaft
= 600 / 30
= 20 / 1
For Modified Sine Motion :

Motion Velocity Factor :
C v = 1.7596 / 1 + (F * 0.7596)
= 1.7596 When F = 0
Motion Acceleration Factor :

= Ca = C v * 3.14 / 1 - F
= 1.7596* 3.14 / 1 When F = 0
= 5.5280
Kinematic Calculation :
Displacement :
S = 2 π r ϴ / 360
Page 46
CHAPTER 4
METHODOLOGY
= 2 * 3.14 * 4.72 * 30 / 360
= 2.470inch
Maximum Velocity :
V max = C v * Displacement / t2
= 1.759 * 2.470 / 1
= 4.34inch / seconds
Maximum Acceleration
A max = C a * Displacement / t2
= 5.528 * 2.470/ 1
= 13.65 inch / second2
Displacement, Velocity, Acceleration and Jerk Graph
Time = 0 to 1second
Indexing 30 degree
Displacement Graph
Graph 4.1 Displacement Graph
Velocity Graph
Page 47
CHAPTER 4
METHODOLOGY
Graph 4.2 Velocity Graph
Acceleration Graph
Graph 4.3 Acceleration Graph

Jerk Graph
Page 48
CHAPTER 4
METHODOLOGY
Graph 4.4 Jerk Graph
Page 49
CHAPTER 5
2-D DRAWING AND MODELING
5 (A) INDEXING PLATE
FIG 5.1 -2-D DRAWING OF INDEXNG PLATE
FIG 5.2- 3-D MODEL OF INDEXNG PLATE
Page 50
CHAPTER 5
5 (B) CYLINDRICAL CAM
FIG 5.3-2-D DRAWING OF CYLINDRICAL CAM
FIG 5.4 -3-D MODEL OF CYLINDRICAL CAM
Page 51
CHAPTER 5
5 (C) ROLLER
FIG 5.5 -2-D DRAWING OF ROLLER
FIG 5.6 - 3-D MODEL OF ROLLER

Page 52
CHAPTER 5
5 (D) FOLLOWER
FIG 5.7- 2-D DRAWING OF FOLLOWER
FIG 5.8-3-D MODEL OF FOLLOWER

Page 53
CHAPTER 5
5 (E) FLANGE
FIG 5.9 - 2-D DRAWING OF FLANGE
FIG 5.10 - 3-D MODEL OF FLANGE
Page 54
CHAPTER 5
5 (F) KEY
FIG 5.11 - 2-D DRAWING OF KEY
FIG 5.12 - 3-D MODEL OF KEY

Page 55
CHAPTER 5
5 (G) SHAFT
FIG 5.13 - 2-D DRAWING OF SHAFT
FIG 5.14 - 3-D MODEL OF SHAFT

Page 56
CHAPTER 5
5 (H) HOUSING OF ROTARY TABLE
FIG 5.15 - 2-D DRAWING OF HOUSING
FIG 5.16 - 3-D MODEL OF HOUSING

Page 57
CHAPTER 5
5 (I) ASSEMBLY OF ROTARY INDEXING TABLE
FIG 5.17 - 3-D MODEL OF ROTARY INDEXING TABLE

ASSEMBLY IN DIFFERENT VIEW
5 (J) EXPLODE VIEW OF ROTARY INDEXING TABLE
FIG 5.18 EXPLODE VIEW OF ROTARY INDEXING

TABLE ASSEMBLY
Page 58
CHAPTER 5
5 (K) FULL ASSEMBLY OF ROTARY INDEXING TABLE
FIG 5.19 3-D MODEL OF FULL ASSEMBLY OF ROTARY

INDEXING TABLE
Page 59
CHAPTER 6
RESULT AND CONCLUSION
Static analysis is done on the Rotary Indexing Table and load on the table is
1000 kg .The values of stress and deformation are obtained.
Meshing of Rotary Table Housing
Fig 6.1 Meshing Of Rotary Table Housing
Fig 6.1 shows the Meshed Model of housing of rotary indexing Table. The
elements used are trias. It is meshed using Ansys 14.5 software.
Boundary Condition- Fixed Support of Rotary Table Housing
Fig 6.2 Fixed Support Of The Rotary Table
Design And Analysis of cylindrical cam with Roller Follower Rotary Indexing table
Page 60
CHAPTER 6
Fig 6.2 Shows that Boundary Condition of Rotary Table Housing, where the
base is kept fixed and load is applied on the upper portion of the housing as
shown in figure 6.3.
Static Structural Loading Condition Of Rotary Table Housing
Fig 6.3 Static Structural Loading Condition
Equivalent Stress generated in Rotary table Housing
Fig 6.4 Equivalent Stress Generated in Rotary Table Housing
Fig 6.4 shows the values of stresses obtained during the static structural
analysis. The maximum value obtained is 6.9102 e5 Pa.
Page 61
CHAPTER 6
Total Deformation Of Rotary Table Housing
Fig 6.5 Total Deformation Of Housing Of Rotary Table
Fig 6.5 shows the total deformation of the housing during its static analysis. The
maximum value obtained is 0.00063742mm.
Conclusions
The obtained results are satisfactory with respect to the velocity, torque,
acceleration and jerk values which are obtained theoretically.
Modified Sine Curve (MSC) is best for cylindrical Cam design.
The time required and the number of setups are reduced.
Scope of Future work

Dynamic Analysis and Fabrication can be done.
Rotary Indexing Table can be developed for Further Machining
Conditions/specifications.
Page 62
REFERENCES
Papers
1. B.Santhosh Kumar, N.Chandrashekhar Reddy, ”Design and analysis of CNC
Rotary Table for Horizontal Machining Center”, International Journal of Research
in Engineering & Advance Technology, Volume 1, Issue 4, Aug-Sep 2013
2. Marian Funaru, Gheorghe Stan, Lucian Mihaila, Marius Pascu, Dragos Andrioaia,
“Precise Rotary Table Indexing system used on Milling Machining Centers”,
Journal of Engineering Studies and Research –Volume 19 (2013) No. 1
3. Suresh Sanap, Ketan Jagtap and Keshav Nandukar, ”Design and Analysis of
Globoidal Cam Index Drive”, International Journal of Scientific Research &
Technology, Volume 2 Issue 3 pp 163-168 June 2013
4. Oh Yeon Taek,” Design of Precision Angular Indexing System for Calibration of
Rotary Tables”, Journal of Mechanical Science and Technology 26(3) (2012)847-
855
5. Dan Cracian, Tiberiu Vesselenyi, Constantin Bungau, Macedom Ganea, Traian
Buidos, Florin Blaga, Iulian Stanase, “Design Solution for Rotary Table for five
axis Machining ”, Annalls of the Orada University Facile of Management and
Technology Engineering ,Issue # 1,May 2013
6. K.M.Mudhita Dassanayake, Masaomi Tsutsumi “High Performance Rotary Table
for Machine Tool Applications”, March 2009.
7. M.B.Vaghela, V.J.Savsani, S.B.Jadeja, “Design and Analysis of Radial Cam and
Globoidal Cam of Tool changing Mechanism used in VMC by using DYNACAM
,International Journal on Mechanical Engineering and Robotics, Issn 2321-
5747,Volume 1,Issue 2, 2013
BOOKS
8. Harold A. Rothbart, Cam Design Handbook
9. Clyde.H.Moon, Camco Commercial Cam Co.Inc.
Page 63
REFERENCES
Catalogues
10. Fibrotor Electro Mechanical Indexing Table
http://www.fibroinc.com/catalogs%20for%20download/FIBROTOR%20EM%20
and%20EM.NC.pdf
11. Autorotor Rotary Indexing Table
http://www.autorotorgroup.com/cd%20eseguibile%20autorotor/cataloghi/TavoleS
erie5.pdf
12. Cam Driven Systems
http://www.cdsindexers.com/rotary-indexing-tables/it-series.html/catalogue
13. Industrial Motion Control
http://www.camcoindex.com/Catalogs/Camco-NA-A-Engineering_051408.pdf
WEBSITES
14. http://en.wikipedia.org/wiki/Rotary_table
15. http://www.ganro.com
16 http://www.weissna.com
17. http://www.camcoindex.com
18. http://www.autorotor.com
19. http://www.fibrotor.com
20. http://www.cdsindxers.com
Page 64

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DESIGN AND ANALYSIS OF CYLINDRICAL

CAM WITH ROLLER FOLLOWER ROTARY

ATMIYA INSTITUTE OF TECHNOLOGY & SCIENCE

Signature and Name of Supervisor Signature and Name

Ravi C. Patel Dr. G.D.Acharya

Signature and Name of Student Signaturre and Name of Guide

Signature and Name of Student Signature and Name of Guide

Vikram Jayantilal Panchal Ravi C. Patel

Signature and Name of Principal

This is to certify thatt research work embodied in this thesis “D

Signature of student: Signature of Guide:

Name of student: Name of Guide:

Vikram Jayantilal Panchal

Atmiya Institute of Technology & Science, Rajkot

1.1 Horizontal Rotary Table 1

1.28 Dwell Rise Return Dwell Cam 17

FIG NO TITLE PAGE.NO

2.2 Result of three Motion curves 34

2.1 Modified Sine Curve 35

2.2 Modified Trapezoidal Curve 35

2.3 Modified Constant Velocity Curve 36

B. COMMENTS FOR DISSETATION PHASE-I (730003) SEM-3rd

1.1 Rotary Indexing Table

Fig. : 1.1 Horizontal Rotary Table

(B) Vertical Rotary Table[14]

Fig. 1.2 Vertical Rotary Table

Fig. 1.3 Tilting Rotary Table

1.2 Rotary Table Based on Operating Mechanism[14]

Fig. 1.4 Pneumatic Operated Rotary Table

1.2.2 Worm gear and Worm Wheel based Rotary Table[14]

1.3 Cam based Rotary Indexing Table[9]

Cam-Operated Indexing Systems have the Following Features and

1.4(A) Based on Cam Shape Classification[8] :

1. Wedge Cam 4. Spherical Cam

1.4(A).1 Wedge Cam[8]

Fig 1.6 Wedge Cam

1.4(A).2 Cylindrical Cam[8]

Fig 1.8 cylindrical cam with indexing turret tapered follower

1.4(A).3 Globoidal Cam[8]

Fig. 1.9 Globoidal Cam

1.4(A).4 Spherical Cam[8]

Fig. 1.10 Spherical Cam

Fig. 1.11 Inverse cam

1.4(A).6 Disk Cam[8]

Fig. 1.12 Disk Cam

1.4(B) Based on Cam Motion Classification[8]

1.4(B).1 Rotating cam[8]

Fig. 1.13 Rotating cam

Fig. 1.14 Translating cam

Fig. 1.15 Stationary cam

1.5(A).1 Roller Follower[8]

Fig. 1.16 Roller Follower

1.5(A).2 Knife-Edge Follower[8]

Fig. 1.17 Knife-Edge Follower

Fig. 1.18 Flat face Follower

Fig. 1.19 Spherical face Follower

Fig. 1.20 Gravity constraint follower

Fig. 1.21 Spring constraint follower

1.5(B).3 Positive constraint[8]