Screw rotor manufacturing via 5-axis flank CNC machining using conical tools

We propose a new method for 5-axis flank computer numerically controlled (CNC) machining of screw rotors using conical tools. The flanks of screw rotors consist of helical surfaces, which predetermines the motion of the milling tool and reduces the search space for tool positioning to only 4-parametric family, which allows a quick search for good initial positions of a given conical tool. We initialize the search by looking at second order line contact between the tool and the helical flank of the rotor. Several positions of the tool are found, covering major part of the flank of the rotor, followed by global optimization that further reduces the tool-surface error and makes sure that there are no gaps between neighboring sweeps of the tool. We demonstrate our approach on several benchmark screw rotors, showing that our approach meets fine industrial tolerances with only few sweeps of the tool.