Disc Tool Profiling for Complex Helical Surfaces Machining using Boolean Envelope Method with Undercutting Problem

Helical cylindrical surfaces with constant pitch are widely used in industry, such as helical teeth gears, air compressor screws, or cutting tools. One of the best practical methods for machining these surfaces is using the disc tool to mill or to grind. This paper presents with detail proposed methods for disc tool profiling and a simulative machining algorithm to evaluate the precision of the disc tool. The machining simulation algorithm has provided a reliable method for assessing the correctness of the cutting tool and confirmed that the disc-tool determined by the proposed method achieves a high accuracy of 0.0076 mm.