TABLE OF CONTENTS The preceding chapters illustrate that there are a number of factors to consider when designing a cam. A great deal of care in design is necessary to obtain a good compromise of all factors, some of which conflict. Once the cam design is complete a whole new set of considerations must be dealt with that involve manufacturing the cam. After all, if your design cannot be successfully machined in metal in a way that reasonably represents the theoretical functions chosen, their benefits will not be realized. Unlike linkages, which are relatively easy to make, cams are a challenge to manufacture properly.
Cams are usually made from strong, hard materials such as medium to high carbon steels (case- or through-hardened) or cast ductile iron or grey cast iron (case-hardened). Cams for low loads and speeds or marine applications are sometimes made of bronze or stainless steel. Even plastic cams are used in such applications as washing machine timers where the cam is merely tripping a switch at the right time. We will concentrate on the higher load-speed situations here for which steel or cast/ductile iron are the only practical choices. These materials range from fairly difficult to very difficult to machine depending on the alloy. At a minimum, a reasonably accurate milling machine is needed to make a cam. A computer controlled machining center is far preferable and is most often the choice for serious cam production.
Cams are typically milled with rotating cutters that in effect...
