Automated CAD Modelling of Cam Profiles and FEA Fatigue Analysis of Cam-Follower Mechanisms

This paper illustrates a method to automate the 3D designing process of Simple harmonic motion (SHM) cam profile in CATIA CAD package. In a more user-friendly approach, a graphical user interface (GUI) is developed, where the users can enter the cam parameters and obtain 3D CAD model as direct result. It is observed that 90% time will be reduced by using this automated designing and also chance of errors also reduces. Due to the high follower load impacting on cam profile, high contact stresses induced on the component surfaces due to the asperity contacts cause the cam or roller surfaces to be subjected to high risk of contact fatigue failure. Present work focuses on comparing fatigue life of SHM and Cycloidal cam functions. The fatigue life is assessed using finite element analysis (FEA) in ANSYS Workbench. We have considered follower as flat-faced and frictionless contact between cam and follower in this study. After developing the 3D model of SHM and cycloidal cam profile through automated method, both the models were then imported to ANSYS for fatigue analysis under the same loading conditions. It has been found that cycloidal function has more fatigue life than SHM function.