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

Moeso Andrianto, Yu Ren Wu, Achmad Arifin

Research output: Contribution to journalArticlepeer-review

3 Scopus citations


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.

Original languageEnglish
Pages (from-to)5015-5029
Number of pages15
JournalInternational Journal of Advanced Manufacturing Technology
Issue number11-12
StatePublished - Apr 2023


  • Normal deviations
  • Roller-gear cam
  • Virtual cutting
  • Whirl-machining


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