Cutter design and the machining strategy to resolve the tooth wear issue for both paired components of single-screw compressors

• Published in: Mechanism and machine theory Vol. 189; p. 105409
• Main Authors: Arifin, Achmad, Chang, Ming-Che, Wu, Yu-Ren
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.11.2023
• Subjects: Flying cutter design; Geometric modeling; Screw rotor machining; Single screw compressors; Star wheel design; Tooth wear issue; Star wheel design; Single screw compressors; Screw rotor machining; Flying cutter design; Geometric modeling; Tooth wear issue
• ISSN: 0094-114X; 1873-3999
• DOI: 10.1016/j.mechmachtheory.2023.105409

•Geometric modeling of both components is established by LEMP and CEMP methods.•Optimization of the contact area is evaluated by uniform design and RBF models.•Disk and flying cutters are designed to cut the star wheel and primary screw rotor.•A virtual cutting method is performed to simulate the suitable machining strategy.•Profile deviation of both paired components is investigated to ISO-3650 standard. A single screw compressor consists of paired components of the primary screw rotor and two star-wheel. It is widely applied in enormous industrial applications and is growing continuously. However, the manufacturing for both paired components, including the tooth surface wear issue, must be solved. This paper proposes geometric modeling of cutter design and the analytical cutting for both paired components, in addition to optimizing the contact area to resolve the tooth wear issue. The geometric modeling of the components was determined in LEMP and CEMP models. The cutter profile designs were designed according to gear enveloping theory and pair meshing conditions. The contact area on the tooth flank was successfully enhanced by applying a uniform design and RBF pseudo model. The virtual machining was accomplished in VERICUT, and the machining strategy for both paired components was verified and suitable for actual CNC machining. In addition, the geometric model's correctness for both cutters was confirmed since the profile deviation on both components satisfied the ISO-3650 standard.