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Prediction model for rapidly generating rotor profile and surface cutting marks by insert-cutting trajectory (ICT) method in screw rotor milling

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Abstract

A robust design of a disk-type milling cutter involving multiple inserted blades is required in screw rotor milling since it significantly influences the machining precision. Hence, it is essential to discover a prediction model for rapidly simulating rotor profiles and cutting marks to evaluate the cutter design to enhance the cost-time savings in cutter manufacturing. This study proposes an insert-cutting trajectory (ICT) method that is resolved by considering the cutting-edge form of each insert type and cutting conditions. In addition, the ICT method’s accuracy is determined according to the number of points on the insert cutting-edge length and the number of grids on the tooth profile length. The result confirms that the rotor profile and the surface cutting marks were successfully generated by applying both disk-type milling cutters with standard and special inserts. The profile results indicate that the special insert can achieve smoother than the round-standard insert. The ICT method relied on the screw rotor milling with distinction cutting conditions utilizing the special inserts. Finally, an experimental result verified that the ICT method is reliable and practicable.

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Data availability

All data generated or analyzed during this study are included in the manuscript.

Code availability

Not applicable.

Abbreviations

\({A}_{3}\) :

Correctional offset

\({f}_{s}\) :

Axial feeding

\({R}_{3},{R}_{4}\) :

Radial offset of special/standard insert position on the cutter wheel

\({s}_{p}\) :

Helical parameter / rotor unit lead

\(S\) :

Rotational speed

\(t\) :

Insert thickness

\({t}_{m}\) :

Machining time

u :

Fitted curve parameter

\({Z}_{3},{Z}_{4}\),:

Axial offset of special/standard insert position on the cutter wheel

\(\alpha\) :

Index angle of insert position on the cutter wheel

\(\beta\) :

Rotational angle of insert position on the cutter wheel

\({\delta }_{q}\) :

Normal deviation

\(\gamma\) :

Setting angle of the cutter wheel and rotor axis

\(\lambda\) :

Inclination angle of insert position on the cutter wheel

\(\psi\) :

Revolve angle of insert position on the cutter wheel

\(\tau\) :

Insert curve parameter

\(\varphi\) :

Rotational angle

\(\phi\) :

Setting angle

\(\theta\) :

Radial surface parameter

c :

Milling cutter

r :

Screw rotor

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Acknowledgements

The authors are grateful to Hanbell Precise Machinery Co., Ltd. in Taiwan for their experimental and technical supports.

Funding

This research was supported by the Ministry of Science and Technology in Taiwan, project number MOST 109–2221-E-008–004-MY2.

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Authors and Affiliations

  1. Department of Mechanical Engineering Educations, Universitas Negeri Yogyakarta, 01, Colombo Rd, Karangmalang, Yogyakarta, 55281, Indonesia

    Achmad Arifin

  2. Department of Mechanical Engineering, National Central University, 300, Zhongda Rd., Zhongli District, 320317, Taoyuan City, Taiwan, Republic of China

    Yu-Ren Wu

  3. Research Center for Appropriate Technology, National Research and Innovation Agency (BRIN), Subang, 41213, Indonesia

    Moeso Andrianto

Authors
  1. Achmad Arifin
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  2. Yu-Ren Wu
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  3. Moeso Andrianto
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Contributions

Achmad Arifin constructed the research design, accomplished the analytical simulation and validated the result, and composed the manuscript; Yu-Ren Wu earned the funding and directed the research implementation, whereas Moeso Andrianto supervised the experimental test and verified the measurement. All authors worked concurrently to proofread and structure the submission.

Corresponding author

Correspondence to Yu-Ren Wu.

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Arifin, A., Wu, YR. & Andrianto, M. Prediction model for rapidly generating rotor profile and surface cutting marks by insert-cutting trajectory (ICT) method in screw rotor milling. Int J Adv Manuf Technol 123, 4137–4152 (2022). https://doi.org/10.1007/s00170-022-10378-x

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  • DOI: https://doi.org/10.1007/s00170-022-10378-x

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