At Rotor Design Solutions, the profile design is carried out with the tooling design as a major consideration. Rotor designs are optimized to ensure radii on cutting tools are large enough to extend tooling life and minimize manufacturing costs, while ensuring excellent component accuracy.
Rotor Design Solutions offer tool design for the following:
- Disk tools for milling and grinding
- Flytools for worm wheels
- Hobs for rotors and gears
The calculation of cutting tools for helical rotors is not simple. For a profile parallel to the axis of the rotor with a zero helix angle, the tool is the same shape as the profile. As the helix angle of the rotor increases from zero, the shape of the cutting tool deviates more and more from the shape of the rotor.
To calculate the tool, requires an iterative function, whereby software is required to guess a location for contact between the tool and the rotor and then mathematically deduce whether this contact location is correct. It will then use the answer from its previous approximation to make a more accurate guess. This will continue until there is zero error. The software developed by Rotor Design Solutions uses the most modern, stable mathematical algorithms to provide a reliable solution for rotor tool calculation.
Videos that demonstrate our software for tool calculation for both form tools and end mills may be found on our rotor software page.