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Mathematical modeling on a novel manufacturing method for roller-gear cams using a whirl-machining process

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Abstract

The whirl-machining process is a precise, efficient, and promising machine process for manufacturing workpieces over the milling process. At the same time, the roller-gear cam has advantages over the other cam-follower system. However, the whirl-machining process has not been applied to manufacture the roller-gear cam. Therefore, this paper proposes a novel method for roller-gear cam manufacturing using a whirl-machining process. Mathematical modeling is described for generating the roller-gear cam, roller, and whirl-milling tool surface. A novel CNC machine and its coordinate system are proposed. Cutting simulations for obtaining the surface topologies and normal deviations are conducted. Globoidal cam with different cylindrical rollers, globoidal cam with a conical roller, and cylindrical cam with a conical roller are taken as case studies, and results are discussed. A virtual cutting simulation was conducted using VERICUT. Some machining examples are shown to verify the benefits of the proposed method in roller-gear cam manufacturing.

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

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Funding

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

Author information

Authors and Affiliations

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

    Moeso Andrianto & Yu-Ren Wu

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

    Moeso Andrianto

  3. Department of Mechanical Engineering Education, Universitas Negeri Yogyakarta, 01, Colombo Rd, Karangmalang, Yogyakarta, 55281, Indonesia

    Achmad Arifin

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

Moeso Andrianto constructed the research design, accomplished the analytical simulation, conducted the virtual simulation, and composed the manuscript. Yu-Ren Wu earned the funding and directed the research implementation, whereas Achmad Arifin supervised the analytical and virtual simulation. All the authors worked concurrently to proofread and structure the submission.

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Correspondence to Yu-Ren Wu.

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Andrianto, M., Wu, YR. & Arifin, A. Mathematical modeling on a novel manufacturing method for roller-gear cams using a whirl-machining process. Int J Adv Manuf Technol 125, 5015–5029 (2023). https://doi.org/10.1007/s00170-023-10990-5

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  • DOI: https://doi.org/10.1007/s00170-023-10990-5

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