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Workpieces with a globoid shape have been used extensively in industry. However, its hourglass shape increases machining difficulty and requires exact accuracy during manufacturing. The issues could be remedied using a different manufacturing procedure to minimize machining difficulties. As a result, our research developed a way to reduce machining challenges. The novelty of the study is the general mathematical model for machining the globoid screw rotor surface. The machining process on both flank surfaces of the workpiece is conducted simultaneously using a disk-type cutting tool. Analytical and virtual cutting simulations on globoid screw rotor surface machining are investigated. The machine setting and the coordinate system are proposed. A mathematical model for the surface of the tool and workpiece is presented. The generation of the workpiece surface on the offered machine is investigated. The machining process simulation of the globoid screw rotor surface by the disk-type cutting tool is performed. The numerical solution of cutting points and the normal deviation of the globoid rotor surface are solved. Sensitivity analysis, additional movements, cutting tool assembly error, and the numerical solution for machine-axis settings using the Levenberg–Marquardt algorithm are conducted. Virtual cutting simulation is presented using VERICUT. Verification of mathematical modeling is performed. The hourglass worm and the roller-gear cam are taken as numerical examples. Results from the machining examples are presented to verify the advantages of manufacturing the globoid rotor surfaces in the proposed method. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]