Study of Optimal Cam Design of Dual-Axle Spring-Loaded Camming Device.

The spring-loaded camming device (SLCD), also known as "friend", is a simple mechanism used to ensure the safety of the climber through fall prevention. SLCD consists of two pairs of opposing cams rotating separately, with one (single-axle SLCD) or two (dual-axle SLCD) pins connecting the opposing cams, a stem, connected to the pins, providing the attachment of the climbing rope, springs, which simultaneously push cams to a fully expanded position, and an operating element controlling the cam position. The expansion of cams is thus adaptable to allow insertion or removal of the device into/from a rock crack. While the pins, stem, operating element, and springs can be considered optimal, the (especially internal) shape of the cam allows space for improvement, especially where the weight is concerned. This paper focuses on optimizing the internal shape of the dual-axle SLCD cam from the perspective of the weight/stiffness trade-off. For this purpose, two computational models are designed and multi-step topology optimization (TOP) are performed. From the computational models' point of view, SLCD is considered symmetric and only one cam is optimized and smoothened using parametric curves. Finally, the load-bearing capacity of the new cam design is analyzed. This work is based on practical industry requirements, and the obtained results will be reflected in a new commercial design of SLCD.

Increasing the Accuracy of Free-Form Surface Multiaxis Milling.

This contribution deals with the accuracy of machining during free-form surface milling using various technologies. The contribution analyzes the accuracy and surface roughness of machined experimental samples using 3-axis, 3 + 2-axis, and 5-axis milling. Experimentation is focusing on the tool axis inclination angle-it is the position of the tool axis relative to the workpiece. When comparing machining accuracy during 3-axis, 3 + 2-axis, and 5-axis milling the highest accuracy (deviation ranging from 0 to 17 µm) was achieved with 5-axis simultaneous milling (inclination angles ßf = 10 to 15°, ßn = 10 to 15°). This contribution is also enriched by comparing a CAD (Computer Aided Design) model with the prediction of milled surface errors in the CAM (Computer Aided Manufacturing) system. This allows us to determine the size of the deviations of the calculated surfaces before the machining process. This prediction is analyzed with real measured deviations on a shaped surface-using optical three-dimensional microscope Alicona Infinite Focus G5.