Influence of Nonlinear Dynamics Behavior of the Roller Follower on the Contact Stress of Polydyne Cam Profile

The effect of the cam profile on the nonlinear dynamics phenomenon of the follower is studied at three involutes’ profiles for the cam. The value of the Lyapunov exponent parameter is calculated at different internal distances of the follower guide from inside and at different cam speeds. The effect of the Lyapunov exponent value on the contact stress is studied based on the clearance between the follower and its guides. The contact between the cam and the square grooving key and between the cam and the follower has been taken into consideration at different locations. The finite element method is used to calculate the contact stress numerically using the SolidWorks program. The nonlinear response of the follower is calculated analytically using the Newton–Euler equations of rigid body dynamics of translation and rotation motions while the follower position is tracked experimentally using a high-speed 3-D camera device. The contact stress is checked and verified using photo-elastic apparatus. The data of the contact stress against time are used in the Wolf algorithm code to extract the value of the largest Lyapunov exponent. A phase-plane diagram is drawn at different cam speeds and different internal distances of the follower guide from the inside. The periodic and non-periodic motions of the contact stress are examined at different contact locations for the follower with the cam profile. The higher the value of contact stress, the higher the value of the largest Lyapunov exponent parameter and the higher the value of bending deflection.