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Optimizing Climbing Cam Design

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Optimizing Climbing Cam Design Optimizing Climbing Cam Design A Major Qualifying Project Submitted to the Faculty of WORCESTER POLYTECHNIC INSTITUTE in partial fulfilment of the requirements for the Degree of Bachelor of Science Submitted By: Nathaniel Shimkus Nicholas Giaquinto Parrish Garver Advisor: Ahmet Can Sabuncu, PhD Department of Mechanical Engineering Abstract The goal of this project is to create a better mechanical design for micro cams, small camming device used in rock climbing, to increase their holding power and safety. As a result of researching ways to create a better micro cam, our team designed a micro cam which was manufactured and tested against international standards. Although the results did not meet the standards required, the micro cam showed promise that signifies the design can be iterated on in the future. i Acknowledgements Our team would like to thank the following individuals for their time and support throughout the completion of this project: Professor Ahmet Can Sabuncu, our advisor who allowed us to conduct this project and gave us guidance along the way Michael Collins, our point of contact in Washburn room 113 who gave us access and assistance to the Instron that was critical in the testing of our project Davis Ladd, a graduate student who worked in Washburn room 113 and gave us assistance and guidance on how to use the Instron Barbara Fuhrman, our point of contact for ordering material and components necessary in the construction of our project James Loiselle, our point of contact in Washburn room 108 who helped us machine the Cable Moment Cam ii Table of Contents Table of Contents Abstract .......................................................................................................................................................................................... i Acknowledgements ................................................................................................................................................................. ii Table of Contents ..................................................................................................................................................................... iii Authorship ................................................................................................................................................................................. vi 1 Introduction ....................................................................................................................................................................... 1 1.1 Stakeholders ................................................................................................................................................................................. 5 1.2 Rock Climbing as a Sport ......................................................................................................................................................... 6 1.3 Locations and Types of Rock .................................................................................................................................................. 7 2 Background ........................................................................................................................................................................ 8 2.1 Parts of a Cam .............................................................................................................................................................................. 9 2.2 Friction ......................................................................................................................................................................................... 10 2.2.1 Amontons Theory ......................................................................................................................................................... 11 2.2.2 Static Friction .................................................................................................................................................................. 12 2.2.3 Dynamic Friction ........................................................................................................................................................... 13 2.3 The Physics of Camming Devices ........................................................................................................................................ 14 2.3.1 The Rigid Cam Model .................................................................................................................................................. 14 2.3.2 The Elastic Cam Model................................................................................................................................................ 17 2.3.3 Non-Parallel Cracks ..................................................................................................................................................... 18 2.3.4 Fall Factors....................................................................................................................................................................... 19 2.3.5 Testing Applied Force ................................................................................................................................................. 22 2.4 Failure Modes of Cams ............................................................................................................................................................ 22 2.4.1 Failure Due to Poor Placement of Cam ................................................................................................................ 22 2.4.2 Failure caused by weather ........................................................................................................................................ 24 2.4.3 Failure due to poor rock quality and lack of friction..................................................................................... 25 2.4.4 Failure due to walking of the cam ......................................................................................................................... 25 2.4.5 Brittle fracture failure ................................................................................................................................................. 26 2.4.6 Head torque failure ...................................................................................................................................................... 27 2.5 Fractals ......................................................................................................................................................................................... 28 3 Project Approach .......................................................................................................................................................... 30 3.1 Client statement ........................................................................................................................................................................ 30 3.2 Goal Statement and Objectives ............................................................................................................................................ 30 3.3 Market Needs.............................................................................................................................................................................. 31 iii 3.4 Functional Requirements ...................................................................................................................................................... 33 3.5 Design Requirements............................................................................................................................................................... 34 3.6 Constraints .................................................................................................................................................................................. 35 4 Design Concepts ............................................................................................................................................................ 37 4.1 Cable Moment Cam .................................................................................................................................................................. 37 4.2 Piston Cam ................................................................................................................................................................................... 38 4.3 Cleat Design ................................................................................................................................................................................ 39 4.4 Ratchet and Pawl Design ....................................................................................................................................................... 40 5 Material Innovations ................................................................................................................................................... 43 5.1 Adhesive Coating ....................................................................................................................................................................... 43 5.2 Fractals ......................................................................................................................................................................................... 43 5.3 Nanowires ...................................................................................................................................................................................
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