Design evaluation of disk-type milling cutter with special inserts applying analytical simulation and the experimental verification in screw rotor milling.

• The unique inserts cutting-edge are generated considering the cutter curve curvature. • A modified cutter coordinate system is constructed with a revolve angle to arrange the insert. • Both cutters with special and round-standard inserts are compared. • A cutting simulation and experimental verification are performed. • Rotor profile and surface topography are investigated to evaluate the cutter design. A milling cutter with inserted blades is designed for each screw rotor since the geometry profile is unique, corresponding to its purposes and function. Correctness in cutter design, including the cutting-edge insert profile, is necessary to achieve a precise rotor profile; therefore, it is essential to introduce an enhanced cutter design. This study proposes a design of a disk-type milling cutter with special inserts. The insert cutting edge was generated on the axial plane considering the cutter curve curvature and then positioned onto the cutter body according to the modified coordinate system with a revolve angle. The analytical cutting result indicates that the simulated profile is relatively even along the gear tooth profile and the normal deviation is significantly tinier than the insert arrangement area. In addition, the cutter design applying special inserts acquires better results than standard inserts. Finally, the experimental result, including the rotor surface topography, confirms that the proposed cutter design is reliable and realistic in CNC screw rotor milling. [Display omitted] [ABSTRACT FROM AUTHOR]