Abstract
The machining precision plays an important role in the operation reliability and service life of screw rotors. However, the actual machined rotor profile of screw rotors is different from its theoretical profile due to the errors of the machine tool. This paper proposes a novel method of error tracing and compensation to reduce the machined errors of rotor profile on the basis of the limited sample trials, and the method is based on a matrix of error compensation. The errors of rotor profile are obtained based on limited sample trials machining of screw rotors,and fitted into piecewise smooth data. A matrix of error compensation is established to compute the errors of rotor profile to generate a compensated rotor profile. The compensated rotor profile is then used to regenerate forming tool and a new rotor product is processed on the same machine tool. And the errors of new rotor profile are smaller and can be reduced within (−0.01 mm, 0.01 mm) after compensations. Finally, the actual machining examples illustrate that the method of error compensation can not only satisfy the machining requirement of high-precision rotors, but also has the characteristics of good stability and applicability.
Highlights
The advantages of twin-screw compressor include high reliability, good adaptability, ease of operation and maintenance, and the ability to transport various mixed liquids
A screw rotor of inferior quality has a negative effect on the fault diagnosis, condition monitoring, and operation maintenance of screw rotors
It is of significant importance to ensure high machining precision of screw rotors
Summary
The advantages of twin-screw compressor include high reliability, good adaptability, ease of operation and maintenance, and the ability to transport various mixed liquids. The machine tool is the compensation object for the indirect compensation method which improves the processing precision of rotor profiles by enhancing the precision of machine tool. For the direct compensation method, recent researches mainly focus on the change of rotor profile under different errors. Stosic et al [6] presented a method of general geometrical definitions of screw machine rotors and their manufacturing tools. A contact line equation between the rotor tooth surface and the forming wheel revolving surface is derived based on the meshing theory, and the calculation method for theoretical edge shape of forming wheel is proposed, which is applicable to both analytical and discrete forms of the rotor profile. The actual machining examples illustrate the method of error compensation which can satisfy the machining requirement of high-precision rotors, and has the characteristics of good stability and applicability
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