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Energies 2020, 13, 6586 10 of 26 2.4.1. Machining Method of the Screw Rotor Screw rotor profile is composed of several curves, and rotor profile makes a spiral motion along the rotor axis to form a screw rotor. The screw rotor has the characteristics of low helical tooth number and large spiral angle. Currently, milling, rolling, grinding, coating method and precision casting are commonly used machining methods for screw rotor [34,35]. The milling processing method is divided into disc cutter processing method and finger cutter processing method. When the screw rotor is processed by disc milling cutter, there is a space interlacing with a certain angle between the tool axis and rotor axis, the disc cutter rotates around the cutter shaft, and the rotor makes a spiral movement. Finger milling cutter processing screw rotors are normally made on vertical milling machines. The cutter axis is perpendicular to the horizontal axis of the rotor when the rotor is machined, the finger shape milling cutter revolves around the cutter axis, at the same time, the rotor motion according to the spiral rotor gear tooth surface characteristics. When the screw rotor is machined using hob, the milling cutter can continuously cut the tooth surface of the rotor, which is the reason that the rotor machining efficiency can be further improved by the rolling process. To ensure the machining efficiency of the rotor and the service life of the cutter, it is required that the shape of the rotor have excellent machining performance and a straight segment cannot appear. Therefore, the processing type of the screw rotor is limited. In addition, the processing of the hob is sophisticated, and the production costs are relatively high, only suitable for small rotor production. The grinding method not only has high machining efficiency but also makes the rotor have a higher precision of tooth surface. The cost of cutting tool is relatively low compared with the cutting tool. Furthermore, the grinding process can be reprocessed on the surface of the rotor surface treated by heat treatment, so that the manufacturing precision of the finished rotor is greatly improved. Moreover, the good stability and forming process of grinding can obtain more reasonable rotor engagement clearance. The grinding process has a deep grinding function, which applies to different types of profile, and it is the leading edge of the current rotor machining technology. 2.4.2. Profiler Design of Rotor Machining Tool It is difficult to process the screw rotor because of the complicated machining principle and the uncontrollable machining process. However, the forming milling method can meet the requirements of both efficiency and machining accuracy and is the most common method of the manufacturing process of the rotor [36]. In order to adapt to the complex helical surfaces of different screw rotors, higher requirements to the cutting edge, process performance and life span of milling tools are put forward, and many scholars have carried out extensive research. Song [37] from Dalian Jiaotong University used the unilateral asymmetric cycloid pin gear arc line as the research object, the milling cutter profile equations were solved using the envelope method. The method of equidistant clearance of the rotor meshing was proposed by modifying the milling cutter blade. Wang [38] established mathematical model of the relative motion trajectory between the cutter and workpiece in the space without instantaneous center envelope milling process and the mathematical relationship model between the cutter path and the workpiece profile. With the development of computer technology, CAD/CAM has been widely used in optimization design of rotor machining tool profile. Shetha et al. [39] presented mathematical analysis as the basis for a CAD/CAM system for design and manufacture of components with helical grooves. The system helps the user design the profile of the tool or the helical groove, and after that analyzes the subsequent machining process. Shan et al. [40] studied the calculation and simulation of the spiral face forming milling cutter and obtained the formula of the milling cutter by using the enveloping principle. Kuang et al. [41,42] developed the contact equation of the contact line between the helical surface and the revolving surfacePDF Image | Development and Application of the Twin Screw Expander
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