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

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.