MACHINE DESIGN - An Integrated Approach, 4th Ed.

Example 7-3-1

EXAMPLE 7-3

Stresses in a Crowned Cam Follower

Problem: A crowned cam roller-follower has a gentle radius transverse to its rolling direction to
eliminate the need for critical alignment of its axis with that of the cam. The cam's radius of
curvature and dynam- ic load vary around its circumference. What is the size of the contact
patch between cam and follower and what are the worst-case stresses?

Given: Roller radius R1  1.000  in

Crown radius R'1  20.000 in (90 deg to roller rad)
Cam curvature R2  3.460  in (radial)
Cam curvature R'2  ∞ in (axial)
Radial load F  250  lbf (normal to contact plane)
Angle between planes of
R1 and R2 θ  0  deg
The parts are hardened steel. Therefore:
6
E  30 10  psi ν  0.28
Assumptions: The relative motion is rolling with < 1% sliding.
Solution: See Mathcad file EX0703.
1. Find the material constants from equation 7.9a.
2
1ν 8 1
Material constants m1  m1  3.072  10  (a)
E psi
m2  m1

2. Two geometry constants are needed from equations 7.19a and b.

  
Geometry 1 1 1 1 1 1
constants A      A  0.6695 in (b)
2  R1 R'1 R2 R'2 
1
2
 1 2 2 
B   
1 1   1  1   
  R 
2  R1 R'1   2 R'2  
 1 1  1 1   (c)
 2  R  R'    R  R'   cos( 2  θ ) 
  1 1  2 2 
1
B  0.6195 in

The angle  is found from their ratio,

ϕ  acos 
B
Angle  ϕ  22.284 deg (d)
A
and used in Table 7-5 to find the factors ka and kb. Cubic interpolation for ka and linear interpolation for kb
gives
ka  3.444 (cubic interpolation)
Factors from
Table 7-5 kb  0.427 (linear interpolation)
(e)

EX0703.xmcd
MACHINE DESIGN - An Integrated Approach, 4th Ed. Example 7-3-2

3. Determine the contact patch dimensions using the material and geometry constants in equations 7.19d.
1
3
Major axis  3 m1  m2 
half-width a  ka   F a  0.089  in
4 A 
1 (f)
3
Minor axis  3 m1  m2 
half-width b  kb   F b  0.011  in
4 A 
where a is the half-width of the major axis, and b is the half-width of the minor axis of the contact patch. The
contact patch area is then

2
Contact area A  π a  b A  0.0031 in (g)

4. The average and maximum contact pressure can now be found from equations 7.18b and c.

F
Average p avg  p avg  81190  psi (h)
pressure A

3
Maximum p max   p avg p max  121785 psi (i)
pressure 2

5. The maximum normal stresses in the center of the contact patch at the surface are then found using equations
7.21a.

σx  2  ν  ( 1  2  ν)   p
b
In-plane  max σx  74110  psi
 a  b

σy  2  ν  ( 1  2  ν)   p
a
 max σy  115874 psi (j)
 a  b

Axial σz  p max σz  121785 psi

These stresses are principal:
σ1  σx σ2  σy σ3  σz

The maximum shear stress associated with them at the surface is

σ1  σ3
τ13  τ13  23837  psi (k)
2

6. The maximum shear stress under the surface on the z-axis is approximately

Max shear stress τ13max  0.34 p max τ13max  41407  psi (l)

7. All of the stresses found so far exist on the centerline of the patch. At the edge of the patch, at the surface,
there will also be a shear stress. Two constants are found from equation 7.21b for this calculation.
b
k3  k3  0.124
a
(m)
1 2 2
k4   a b k4  0.992
a

EX0703.xmcd
MACHINE DESIGN - An Integrated Approach, 4th Ed. Example 7-3-3

These constants are used in equations 7.21c and d to find the shear stresses on the surface at the ends of
the major and minor axes.

   atanh k4  1  p max

k3 1
Major axis τxy  ( 1  2  ν)  (n)
k4
2  k4 

τxy  12135  psi

k3  k3  k4  
Minor axis τxy  ( 1  2  ν)  1   atan    pmax (o)
k4
2  k4  k3  

τxy  5528 psi

EX0703.xmcd