Screw Compressor Rotor Grinding with Integrated Deburring

Solution Overview

Problem

The high production costs and time required to achieve accuracy in manufacturing screw compressor rotors with helical profiles are due to the need for separate deburring processes, which increase the overall cost and complexity of the manufacturing process.

Innovation Solution

A method combining continuous generating grinding with profile grinding using a worm-shaped grinding tool for roughing and a profile grinding wheel for finishing, integrated with a deburring process using rotating brushes within the same grinding machine setup, allowing for a single clamping and reduced processing time without compromising accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If separate deburring processes are used after grinding, then burr removal is achieved, but production costs and processing time increase

Engineering Contradiction:

Improveburr removalVSAvoidproduction cost and time

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent combines the deburring function with the grinding wheel by integrating abrasive material at the periphery of the grinding wheel. This allows burr removal to be performed simultaneously with or immediately after grinding in a single clamping operation, eliminating the need for separate deburring processes and reducing both production time and costs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The grinding wheel is designed to perform multiple functions: both grinding the workpiece to achieve the desired contour and removing burrs from the same workpiece. By equipping the grinding wheel with peripheral abrasive material, it becomes a multi-functional tool that combines finishing and deburring operations, thereby improving productivity without compromising quality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple separate processing steps are used for grinding and deburring, then each operation can be optimized, but device complexity increases

Engineering Contradiction:

Improvegrinding accuracyVSAvoidnumber of processing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the grinding and deburring operations into a single integrated process using one grinding wheel with peripheral abrasive material. This reduces the number of processing steps from two separate operations (grinding followed by separate deburring) to one combined operation, simplifying the manufacturing process while maintaining the precision benefits of grinding.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If multiple separate machines are used for grinding and deburring, then each machine can be specialized, but the manufacturing process becomes more complex and expensive

Engineering Contradiction:

Improvegrinding accuracyVSAvoidnumber of machines

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The grinding wheel is designed to perform multiple functions: both grinding the workpiece to achieve the desired contour and removing burrs from the same workpiece. By equipping the grinding wheel with peripheral abrasive material, it becomes a multi-functional tool that combines finishing and deburring operations, thereby improving productivity without compromising quality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the deburring function with the grinding wheel by integrating abrasive material at the periphery of the grinding wheel. This allows burr removal to be performed simultaneously with or immediately after grinding in a single clamping operation, eliminating the need for separate deburring processes and reducing both production time and costs.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces manufacturing costs and time while maintaining high accuracy and surface quality, eliminating the need for separate deburring machines and manual processes.

Implementation Method 1

profile grinding of the workpiece (1) in a profile grinding process with a profile grinding wheel (4)

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

a deburring process is carried out on the ground profile (2). The deburring process can be carried out by one or more rotating brushes

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP2149425B1Method and apparatus for producing a screw compressor rotor

Publication Date: 2016.10.12 KAPP GMBH & CO KG WERKZ MASCHFAB

AI summary

The invention relates to a method for manufacturing a screw compressor rotor (1) with a cylindrical base contour, on the outer circumference of which a helical profile (2) is arranged, comprising the steps: a) pre-machining the workpiece (1) by introducing the profile (2) with an excess material relative to the final contour, b) pre-grinding the profile (2) in a roughing operation in a grinding machine, in which part of the excess material is removed, and c) finish grinding the profile (2) in a finishing operation in the grinding machine, in which the remainder of the excess material is removed and the final contour of the profile (2) is produced.In order to increase the economic efficiency in the manufacture of screw compressor rotors in particular, while still ensuring high machining quality, the invention provides that the pre-grinding and/or finish grinding is carried out with a helical grinding tool (3) in a continuous rolling grinding process.