Abstract: Size synthesis about disc cam mechanisms with planar-general-motion roller follower are summarized as two kinds, then the accurate description of these mechanism synthesis tasks are concluded. The first mechanism synthesis task is solved by means of the concept of “virtual oscillating follower”. The universal thought, method and step of the second mechanism synthesis task are proposed by introducing a German high speed printing machine as an example. A set of analytical formulae of the determination of the “instantaneous nested interval” and the “whole nested interval” are proposed firstly by the coordinate establishment, the “floating number axis” and the division of work travel. The existence and its analytical criterion of these formulae are proposed, and then the method to determinate the allowable area for roller center and the value range of the cam’s base circle radius are obtained. A mechanism synthesis example is displayed.

Key words: Base circle radius, Floating number axis, Instantaneous nested interval, Virtual oscillating follower, Whole nested interval, CBN-WC-10Co, cutting force, cutting performance, material removal rate, scratch topography, single fiber cutting