Optimization Design Of The Efficient Hard Alloy Rotor Form Milling Cutter And Manufacturing Technology Of The Rotor

At present, most of the manufacturing enterprise uses the form milling cutters to machine the spiral curved surface of the screw rotor, which greatly improves the machining efficiency and machining quality of the screw rotor. But, the strongly specialized form milling cutters are too difficult to change into the corresponding shape in time when the processing parts are changed. So, it’s necessary to put forward an efficient and general method to design the form milling cutters. This paper has accomplished the following three pieces of works:Firstly, this paper gives a brief introduction and analysis of the background and the development tendency of the form milling cutters. On the basis of the research of the forming principle of the cylindrical spiral surface and the design theory of the forming tool of the spiral groove, the paper takes the rotor whose end profile is known as an example to set up the mathematical model of the calculation method from the data of the end profile of the work-piece to the data of the theoretical profile of form milling cutter, then using the MATLAB software to program to calculate the theoretical profile of the cutter and the coordinate of the blade groove, combining the structural design of milling cutter, completing the three-dimensional modeling of the form milling cutter.Secondly, this paper puts forward three optimized methods to design the form milling cutter whose profile is known, and then these methods are practically used to complete the establishment of the cutter’s model, then, a finite element analysis of the index-able inserts and the two cutters designed by using different methods is followed by to check the strength of the blade and to verify whether the optimization method is feasible or not.Thirdly, by integrated using of the two designing methods, the paper specifically completes the design of the male and female rotor with a particular model, gives the part drawing and the three-dimensional model of them and carries out the machining tests in actual processing environment, which gives out the reasonable range of the milling depth. These data and analytic results will be the reference in both designing and manufacturing process of the cutter and rotor in the future.