Achmad Arifin, Yu-Ren Wu, Zeng Minjun
A variable-pitch screw rotor, whose pitch changes gradually along its axial length, is often used to enhance pump compression efficiency. The turning process can effectively cut the rotor using an appropriately designed cutting tool. A well-designed cutting-edge profile tailored to the rotor tooth profile is crucial for further study, especially in optimizing chip-breaking performance. This study introduces a cutting tool profile with a chip breaker design for manufacturing vacuum pump screw rotors with variable-pitch. The cutting-edge geometry, constructed based on the instantaneous contact line between the tool and the screw rotor, is adaptable to various rotor designs. The paired rotor tooth surface was modified by adjusting the meshing clearance to counter the adverse effect of the variable-pitch on the meshing clearance. The cutting method was demonstrated through analytical cutting and virtual machining, showcasing the design’s adaptability. The cutting results on linear and nonlinear variable-pitch indicate that the maximum normal deviation analysis is satisfied, confirming the correctness of the mathematical model. The initial design of the tool chip breakers demonstrates that the material removal rates exhibited by distinct curve segments during the cutting process vary, leading to chips being broken at varying rotation angles. The potential for enhancing chip-breaking performance by optimizing design factors such as groove width, entry angle, and edge width exists. © The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2025.
Department of Mechanical Engineering Education, Universitas Negeri Yogyakarta, 01, Colombo Rd, Karangmalang, Yogyakarta, 55281, Indonesia; Department of Mechanical Engineering, National Central University, 300, Zhongda Rd., Zhongli District, Taoyuan City, 320317, Taiwan; Center for Eco-material Engineering and Manufacturing, Universitas Negeri Yogyakarta, 01, Colombo Rd, Karangmalang, Yogyakarta, 55281, Indonesia
