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A novel general mathematical model for machining globoid screw rotor surfaces using a disk-type cutting tool

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Abstract

Workpieces with a globoid shape have been used extensively in industry. However, its hourglass shape increases machining difficulty and requires exact accuracy during manufacturing. The issues could be remedied using a different manufacturing procedure to minimize machining difficulties. As a result, our research developed a way to reduce machining challenges. The novelty of the study is the general mathematical model for machining the globoid screw rotor surface. The machining process on both flank surfaces of the workpiece is conducted simultaneously using a disk-type cutting tool. Analytical and virtual cutting simulations on globoid screw rotor surface machining are investigated. The machine setting and the coordinate system are proposed. A mathematical model for the surface of the tool and workpiece is presented. The generation of the workpiece surface on the offered machine is investigated. The machining process simulation of the globoid screw rotor surface by the disk-type cutting tool is performed. The numerical solution of cutting points and the normal deviation of the globoid rotor surface are solved. Sensitivity analysis, additional movements, cutting tool assembly error, and the numerical solution for machine-axis settings using the Levenberg–Marquardt algorithm are conducted. Virtual cutting simulation is presented using VERICUT. Verification of mathematical modeling is performed. The hourglass worm and the roller-gear cam are taken as numerical examples. Results from the machining examples are presented to verify the advantages of manufacturing the globoid rotor surfaces in the proposed method.

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

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Funding

The authors express sincere gratitude to the National Science and Technology Council (NSTC) in Taiwan (R.O.C.) for its financial support under project number: 111-2221-E-008-076-MY2.

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Authors and Affiliations

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

    Moeso Andrianto

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

    Yu-Ren Wu

  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 (main contributor); Yu-Ren Wu earned the funding and directed the research implementation, whereas Achmad Arifin supervised the analytical and virtual simulation. All 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. A novel general mathematical model for machining globoid screw rotor surfaces using a disk-type cutting tool. Int J Adv Manuf Technol 130, 4769–4789 (2024). https://doi.org/10.1007/s00170-024-13000-4

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