Simulation of whirling process and tool profiling for machining of worms

In comparison with machining of worm on a lathe or on a milling machine, whirling process uses a rotating tool ring carrying tools and encompassing the work blank. Due to nature of contact between tool and work blank, simulation of whirling process is necessary to understand the geometry of worm surface generated. In this paper, an attempt is made to simulate the whirling process and analyze the effect of tilting of tool head. In some applications worm geometry is specified and tool geometry has to be arrived at. An approach for profiling of tool is explained in this paper and validation of tool profile is carried out by simulation. Two worms, namely straight-sided in axial section and involute helicoid are taken as case studies and results are discussed.