Cylindrical cam help.

[bearBYYS8]

I have watched tutorials on CADWhisperer's (@JDMather )youtube channel. I keep running into issues trying to create a cam development on the end of a cylinder. I have created a endmill cutter and toolpath offset using the radius of the cutter size. I will post the .ipt, print picture and a actual part picture in the next post. Thank you for any help you can provide.

[bearBYYS8]

Here is the part file, cam print and a picture of the part. A pin needs to sit across both sides of the cam surfaces creating a cam lock mechanism. If at all possible I would like to sweep the cam surface in a 180° sweep so I know the pin will mate with both cam surfaces correctly. You can see on the actual part, the pin is not riding full contact on the cam surface. Thanks.

[JDMather · Accepted solution]

I would do the complex geometry before doing anything else.

I noticed that your sketches are not well defined and Sketch5 indicates unresolved issues.

This will be a complete redo right from the start.

Could take a while as I have my real job to do too.

Repeated dimensions are never a good sign!

[JDMather]

What is the purpose of Extrusion10?

Is this a correction - or is it to add material to casting for machining back to the XZ Plane?

[bearBYYS8]

I have much to learn about defining sketches and creating proper constraints. Would a full print help with creating a properly defined drawing. I would prefer to directly message this to you if needed.

[bearBYYS8]

I was intending to add some material to the length of the extrusion so there was material to remove using the sweep. I wasn't able to extend the original extrusion do to errors in resolving the rest of the model tree. Thanks.

[JDMather]

Your first sketch (and every sketch after that) should be neat and simple.

Something like this.

It is this simplicity that would permit understanding of my process for the Displacement Diagram for the cam feature.

[bearBYYS8]

Understandable. I have a nasty habit of clicking the auto constraint to lock everything in. I have always tried to keep drawings organized and neat, I guess the sketches were always hidden in the model so I wouldn't clean them up. I will start again and take time to keep sketches defined and neat.

[bearBYYS8]

Is something like this still overly complicated?

 

[JDMather]

Yes,

and more importantly - it is not fully defined.

[bearBYYS8]

I am continuing to review basic videos on how to define a sketch properly. I think the sketches are still quite complicated, but progress is being made. I have taken away much of the design to focus on the geometry that is most difficult for me to create. I have attached the latest cam model and a screenshot of the part. I would like to be able to run a horizontal pin across both cam surfaces to see how the interference would be and if the pin would make contact as it should. I think it will as the cam surfaces were created by a single pin sweep. I am not sure how to examine this, but will go back and watch videos on how you have.  Thank you again.

Below is an earlier attempt using emboss. It was a failure.

[JDMather]

I think that you almost have it.

I want to take a close look at this and get it right - but I will not have time till this weekend.

[bearBYYS8]

I have set up a simulation to keep the pin on the correct axis as it travels down the cam surface. I think the reason it looks wrong in the screenshot you captured is I added .02" R to the tips as called out on the drawing. I could not get any of the radius to sweep so I removed everything and added them after the sweep. The 3/32 radii and the .02 radii are not correct, but the 3/32 is not functional and the .02 is more of an edge brake than anything. 

I also think the upper catch the pin sits in is undercutting the upper most shelf surface of the cam. It sits correctly on the cam surface, sits correctly at the first upper "shelf" and sits correctly in the second upper pin resting position catch. You pointed me in the correct direction and I could not have done it without the youtube videos you have produced. Now to attach the rest of the body.