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One of the main factors of the drum brake performance and quality is the accuracy of “S” profiles of the cam shafts. To reduce cost, most axle and brake manufacturers use cam shafts with forged “S” cams, in some cases decreasing the accuracy of “S” profile, brake performance, and quality as compared to a machined “S” profile option. Today's highly competitive market, especially the bus market, requires the highest possible brake performance at reduced cost. This paper shows how to meet both requirements for cam shaft manufacturing, high “S” profile accuracy and low machining cost, at the same time.

One of the greatest problems in city traffic today is congestion. In reducing it, a significant role can be played by improving mass transportation by increased involvement of buses. To entice people to mass transit, it is necessary to increase passengers' comfort. From the technical side, this purpose is served by low-floor buses. To produce them, “portal”* axles are necessary. Besides comfort, vehicles must meet environment protection guidelines including the requirement for quiet operation. In building city buses to meet the new requirements, a significant role is given to the axles. One of the noise sources in buses is the system of gears in the drive axle. The noise coming from this source can be reduced by increasing the “contact ratio” of the gears, by applying fine-module hypoid gear sets in the head assemblies, by introducing so-called “high” gearing with increased contact ratio in the spur gear drives, and by increasing the production accuracy.