Analytical design of disk-type milling cutter with multiple inserts and CNC milling simulation of screw rotors considering grinding stock

A practical method to ensure precisely inserts arrangement onto the cutter body is required since it has a decisive impact on the rotor profile accuracy. Correctness evaluation of applying the cutter concerning the deviation of the generated profile is also essential. This study proposes a novel approach to accurately determine insert position on disk-type milling cutters and its application for screw rotor machining using a CNC rotor milling machine. The proposed method considered a revolved-enlarged rotor, standard round inserts with a slight identical inclination angle and correctional offset. An analytical cutting was performed to acquire the simulated rotor profiles considering the inserts cutting trajectory then predict normal deviation and surface topography. The result shows that the inserts were precisely installed, the deviation position on the simulated profile for the male and female rotor can be controlled for eliminating surface undercut, and the surface topography was satisfactory. Therefore, grinding performance can be enhanced. It indicates that the proposed approach of insert arrangement and its cutting simulation is verified conclusively, and the designed disk-type milling cutter is entirely practicable.