Disc tool profiling for air compressor screws with complex characteristic curves

One of the best practical methods to machine the air compressor screw pairs is milling or grinding by disc tools. The mathematics involved in disc tool profiling is quite complex and requires representing the machined surface by mathematical equations without any singular points and undercutting. From a technical perspective, this article proposes the disc tool profiling integrated solution for machining complex profile screws from their reverse engineering data, which contains crucial issues such as machining deviation evaluation due to undercutting, appropriate tool position setting. The disc tool surface designed by the proposed method is highly accurate, leading the RMS error of the machined surface is less than 0.0201 mm. A difference of the angle, formed by the disc tool axis and the workpiece axis, less than 0.16°, is acceptable in air compressor technology, which leads to a machined surface RMS deviation of less than 0.0186 mm.