This paper presents a software cam manufacturing system. It includes a position tracking control system, a programmable cam profile, and a programmable variable angular velocity profile. The position tracking system consists of a rotary direct drive (DD) servo motor and a linear servo-motor. The rotary DD servo-motor is controlled to track the variable angular velocity profile, while the linear servo-motor is controlled to synchronously track the desired cam profile. Such a tracking control system is proposed to achieve a constant removal rate for fine machining (i.e., the relative tangential velocity at the contact point should be constant). A numerical method for off-line derivation of the variable angular velocity profile with respect to the desired cam profile is developed to achieve constant relative tangential velocity at the contact point. An experimental tracking control system with two servo controllers is developed to study the feasibility of this approach.

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