Model-based tool design for the manufacturing of hypocycloidal internal profiles by polygon turning

Polygon turning is a machining process for manufacturing internal and external hypocycloidal profiles, which are becoming increasingly important for shaft-hub-connections. The highly productive process can be integrated on lathe machines. Existing analytical models are not sufficient to address the main challenge when designing tools for manufacturing internal profiles. In this work a dexel-based numerical approach is presented to calculate the limits of tool design. The findings are made usable for tool design with an analogy model and are finally validated experimentally using an alternative drive system for bone screws as an example.