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研究生： 明智
Achmad Arifin
論文名稱： 以鑲刃式刀盤進行螺桿轉子成形銑削之解析數學模型建立與實驗驗證
Analytical modeling and experimental verification of the screw rotor milling utilizing the forming cutter with inserted blades
指導教授： 吳育仁
Wu Yu-Ren
口試委員:
學位類別： 博士
Doctor
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2022
畢業學年度： 110
語文別： 英文
論文頁數： 131
中文關鍵詞： 刀片切削軌跡 、銑刀設計 、多目標優化 、粒子群優化 、徑向基本函數 、螺桿轉子銑削 、統一設計方法
外文關鍵詞： inserts cutting trajectory, milling cutter design, multi-objective optimization, particle swarm optimization, radial basic function, screw rotor milling, uniform design method
相關次數： 點閱：11  下載：0 
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    • 螺桿轉子壓縮機由公轉子和母轉子組成，通常在銑削中用於粗加工和磨削用於精加工。帶刀片的刀具適用於螺桿轉子銑削。由於幾何輪廓獨特，每個螺桿轉子輪廓都需要獨特的銑刀設計。需要穩健的刀具設計，包括刀體上的刀片，因為它顯著影響加工精度。因此，研究使用帶有多個刀片（標准或特殊刀片）的盤式銑刀進行銑削操作的螺桿轉子切削是必不可少的。本研究提出了刀片位置確定方法和刀具設計優化模型的解析設計。此外，研究了一種通過刀片切削軌跡法快速獲取模擬轉子輪廓和切削痕的預測模型。這項研究是通過研究螺桿轉子加工的基本概念，包括轉子幾何輪廓和銑刀特性，以一般方法完成的。分析模型包括改進的刀具坯料和刀體輪廓生成方法、刀片安裝到刀體上的新方法、CNC機床模型上的螺桿轉子切削、快速生成模擬轉子輪廓和切削痕的ICT方法以及計算方法通過推導數學方程和程序源代碼建立了轉子輪廓評估。隨後，通過執行螺桿轉子切削模擬（包括 Vericut 軟件的虛擬加工）來檢驗分析模型，並根據理論設計評估模擬結果。最後，進行了實驗測試，以驗證分析設計和模擬結果。結果表明，所有提出的分析模型都是可靠且完全可行的，因為它們成功地達到了它們的目的和功能。

    Screw rotor compressor consists of male and female rotors commonly manufactured in milling for roughing and grinding for finishing. A cutter with inserts is suitably applied in screw rotor milling. Since the geometry profile is unique, each screw rotor profile requires a distinct milling cutter design. A robust cutter design, including the inserts onto the cutter body, is required since it significantly influences the machining precision. Hence, a study on screw rotor cutting by milling operation using a disk-type milling cutter with multiple inserts, either standard or special, is essential. This study proposes an analytical design for the insert position establishment method and cutter design optimization model. In addition, a prediction model for rapidly acquiring a simulated rotor profile and cutting marks by the insert cutting trajectory method is studied. The research was accomplished in a general approach by studying the basic concepts of the screw rotor machining, including the rotor geometry profile and milling cutter characteristics. The analytical model consisting of a modified method for generating cutter stock and body profiles, a novel method for inserts establishment onto cutter body, screw rotor cutting on CNC machine model, ICT method for rapidly generating simulated rotor profile and cutting marks, and calculation method for rotor profile evaluation by deriving mathematical equations and the program source codes were established. Subsequently, the analytical models were examined by performing the screw rotor cutting simulation, including the virtual machining by Vericut software, and evaluating the simulated result according to the theoretical design. Finally, an experimental test was conducted to verify the analytical design and simulated results. The results indicate that all the proposed analytical models are reliable and entirely practicable since they successfully reach their purposes and functions.

    Table of Contents Information ii Abstract iii Graphical Abstract v Acknowledgment vi Table of Contents vii List of Figures x List of Tables xiii Nomenclature xiv Chapter 1 Introduction 1.1. Background and motivation 1 1.2. Literature review 2 1.3. Novelties and contributions 6 1.4. Research Objectives and Approaches 7 1.5. Dissertation writing structure 8 Chapter 2 Mathematical model of cutter design and screw rotors cutting 2.1. Generation of cutter stock and body profile curves 9 2.1.1. Screw rotor profile generation considering declination angle and grinding allowance 9 2.1.2. The generalized coordinate system for movement involvement among screw rotor and cutter body 11 2.1.3. Derivation of cutter stock and body profiles 12 2.2. Novel method for inserts establishment on the milling cutter body 14 2.2.1. Milling cutter with round standard insert 15 2.2.2. Technical steps of multiple inserts establishment 17 2.2.3. Milling cutter with special insert 23 2.3. Analytical method for screw cutting simulation on CNC Rotor Milling Machine 30 2.3.1. Cutter workpiece engagement in screw rotor milling 31 2.3.2. Motion relation and the coordinate system of CNC rotor milling machine 32 2.3.3. Cutting conditions consideration 33 2.3.4. Generation of the milling cutter path 36 2.4. Principle of the insert cutting trajectory (ICT) method 38 2.4.1. General preparation 39 2.4.2. Generation of simulated rotor profile 40 2.4.3. Prediction of surface cutting marks 42 2.5. Calculation method for rotor profile evaluation 43 2.5.1. Normal deviation 43 2.5.2. Surface topography 45 2.5.3. Grinding stock amount 46 Chapter 3 Integrated multi-objective optimization on geometrical cutter design 3.1. The parametric design of milling cutter geometry 47 3.2. Application of the cutter design process by integration multi-objectives model 48 3.2.1. Definition of the critical design factors and the domain constraints 49 3.2.2. Cutting simulation design and the execution 50 3.2.3. Approximation modeling applying Radial Basis Function (RBF) 51 3.2.4. Estimation and optimization of advantageous response applying PSO algorithm 55 Chapter 4 Numerical examples and discussion 4.1. Analytical screw cutting simulation and verification 58 4.2. Analytical design of disk-type milling cutter with multiple standard inserts 62 4.2.1. Novel method validation of multiple inserts establishment 62 4.2.2. Impact of normal deviation position considering correctional offset 64 4.2.3. Surface topography evaluation on the simulated rotor profile 65 4.3. Comparison analysis of the simulated profile and virtual machining verification 67 4.4. Analytical study of geometrical impact on the cutter design parameters 69 4.4.1. Investigating for distinct inclination angle impact 70 4.4.2. Investigating for distinct gap impact of insert arrangement region 71 4.5. Optimized cutter design evaluation and cutting simulation verification 73 4.5.1. Designing actual milling cutter and virtual machining validation 73 4.5.2. Analytical cutting validation and optimization performance analysis 75 4.6. Design evaluation of disk-type milling cutter with special inserts 79 4.6.1. Correctness analysis for the milling cutter design with special inserts 79 4.6.2. Comparison of both milling cutters with special and standard inserts 82 4.6.3. Screw rotor milling verification by experimental 83 4.6.4. Surface topography evaluation on both simulated and machined rotor surface profiles 87 4.7. Prediction model for generating rotor profile and surface cutting marks by insert cutting trajectory (ICT) method 90 4.7.1. Correctness analysis involving both milling cutter with standard and special inserts 90 4.7.2. Evaluation of the prediction model on distinctive cutting conditions 93 4.7.3. Verification of the prediction model on screw rotor milling by the experimental test 96 Chapter 5 Conclusion and Future works 5.1. Conclusion 98 5.2. Future works 99 5.2.1. Prediction model of cutting force and insert life time in screw rotor milling applying cutter with inserted blades 99 5.2.2. Prediction and analysis of cutting chip result in screw rotor milling applying CAD model 101 5.3. List of Publications 102 References

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