Chapter 3 Calculation of Geometric Characteristics

The geometric characteristics of screw compressors mainly include length of

contact line, blowhole area, inter-tooth area, inter-tooth space, area of suction and
discharge ports, length of the sealing strand on addendum etc. The calculation of these
factors, lays the foundation for the accurate prediction of the thermodynamic
performance as well as the analysis of dynamic property of screw compressors, which
is very significant for the optimal design of screw compressors. This chapter is to
analyze and calculate some important geometric characteristics based on the
introduction of equations for helical surfaces.

3.1 Helical Surface and Its Normal

3.1.1 Equation for Helical Surfaces

Usually the rectangular coordinate of curved surface S can be expressed in the

following parametric equation:
x = x(t ,τ )
y = y (t ,τ ) (3-1)
z = z (t ,τ )

Or in vector expression
r = r (t ,τ ) The equation
for curved surface contains two
parameters (t, ). The variation
change of these two parameters (t, )
must be known to decide the
boundary of the curved surface.
As discussed above, the rotor
helical surface of screw compressors
is the helical surface formed while
the rotor profile performs helical
motion. As in Fig 3-1, suppose the
parametric equation of segment c of
rotor profile is

Fig 3-1 Helical Surface and Its Coordinate System

55
x0=x0 (t); y0=y0 (t). Segment c rotates round the axe of rotor profile, thus forming the
rotor helical surface corresponding to this end profile.

Considering the plane segment c is initial in as plane Oxy, correspondingly,

there will be axis Ox and Oy, and the helical axis as axis Oz, therefore obtaining
spatial rectangular coordinate system Oxyz.

As segment c rotates round Oz to position c’, the axial advance range is z, and
is the intersection angle towards the initial position. Thus the position of c’ in
coordinate system O’x0y0z is that of c in Oxyz, the corresponding equation for the
right helical surface is expressed as

x = x0 (t ) cos τ − y 0 (t ) sin τ
y = x0 (t ) sin τ + y 0 (t ) cos τ (3-2)
z = pτ

T
And p=
2π

In the above equation, p stands for the steepness of the helical surface, called
helical characteristic quantity. T is advance range of segment c rotating round axis z
for one cycle (2 ), called axial pitch distance or lead. In addition, segment c rotates
round axis z from one end plane of the rotor to the other, obtaining an angular
measure z which is called torsion angle. Suppose the length of effective working
segment of rotor is L, then,

L
z= 2π
T

Similarly, the equation for left helical surface is

x = x0 (t ) cos τ + y 0 (t ) sin τ
y = − x0 (t ) sin τ + y 0 (t ) cos τ (3-3)
z = pτ

In (3-2) and (3-3) mentioned above, if = c=constant, then z=p c=constant,

thus obtaining a plane normal to axis z, and the transversal section between this plane
and the helical surface is a segment rotating with an angular measure for c. If =0,
substituted into (3-2) or (3-3), the equation obtained here stands for the initial position
of segment c.

If the parameter t=tc in the equation for helical surface is a constant, it stands
for a helix formed by the rotation of a fixed point (xc,yc). t can represent different

56
constants, thus obtaining
numerous helixes, uniform into
one helical surface.According to
the coordinate system for
segments of male and female
rotors in Fig 3-2, O2x2y2z2 and
O1x1y1z1 standing for the
consolidations respectively on
female rotor and male rotor, is
the moving coordinate system
rotating with male and female
rotors. O2X2Y2Z2 and O1X1Y1Z1
express the consolidations on the
housing, and the static
coordinate system. Moreover, all
the planes of the coordinate
system should be positioned on
the suction end of the rotors, and
then based on Eq (3-2) and Eq
(3-3), the following equation for
helical surface of male and
female rotors under different
conditions can be obtained:

Fig 3-2 Coordinate System for Segments

1) Female rotor rotates left

x 2 = x 2 (t ) cos τ − y 2 (t ) sin τ
y 2 = x 2 (t ) sin τ + y 2 (t ) cos τ (3-4)
z 2 = p 2τ

2) Female rotor rotates right

x 2 = x 2 (t ) cos τ + y 2 (t ) sin τ
y 2 = − x 2 (t ) sin τ + y 2 (t ) cos τ (3-5)
z 2 = p 2τ

3) Male rotor rotates left

x1 = x1 (t ) cosτ + y1 (t ) sin τ
y1 = − x1 (t ) sin τ + y1 (t ) cos τ (3-6)
z1 = p1τ

57
4) Male rotor rotates right

x1 = x1 (t ) cos τ − y1 (t ) sin τ
y1 = x1 (t ) sin τ + y1 (t ) cos τ (3-7)
z1 = p1τ

In the above four equations, x2(t), y2 (t), x1(t) and y1 (t) are the
corresponding equations for rotor profile.

3.1.2 Correlations for Basic Geometric Parameter s of Rotors

The helical surface of screw compressors is an equiaxial-pitch cylindrical

surface of revolution with, so all the points in the segments have the same angular
velocity, which shows that every helix on the same helical surface has the same axial
pitch or lead.

The equiaxial-pitch cylindrical surface of revolution has the following

correlation on the coaxial cylindrical surface:

T = 2πR cot β (3-8)

In the above equation, T—— is the axial pitch or lead of any helix on the
cylindrical surface with a radius of R;

R—— is the radius of the cylindrical surface where the helix is;

—— is the helix angle, i.e. the angle between the tangent of helix and the
generatrix of the cylinder.

As the axial pitch of every helix on the same helical surface remains
unchanged, it is obtained from (3-8) that cylindrical surfaces with different radiuses
shall result in different helix angles.

The helical motion of a point can be considered as superpose of its rotation

round the circle and axial motion. Therefore, when the point rotates one cycle round
the axis, it must have covered one axial pitch in the axial direction. According to the
requirements of inter-meshing of the male and female rotor surface, the following
correlation is compulsory:

58
T1n1 = T2n2 = Tn = constant value

In which, T2, T1 are the leads of respective female rotor and male rotor

n2, n1 are the rotating speeds of female rotor and male rotor

Thus the equation can be T1/T2=n2/n1=ϕ2/ϕ1=i

And also because the inter-meshing rotors covered same number of their rotor teeth
within the same time, i.e.

n1z1 = n2z2

Hence obtaining T1/z1 = T2/z2 = T/z = constant value (3-9)

Sometimes the ratio T/z of axial pitch of rotors to number of rotor teeth is
called inter-tooth axial pitch.

According to the relation among lead, helical performance number and torsion
angle, it is obtained

T1/T2 = p1/p2 = τ2z/τ1z = i (3-10)

Besides, it is known from (3-8) that the helix angle of each helix on the same
helical surface is different. However, the helix on the surface of pitch cylinder of
female and male rotor can be obtained through (3-8):

T1 2πR1t cot β 1t cot β1t

= =i
T2 2πR2t cot β 2t cot β 2t

cot β 1t
Substituted into (3-10) to obtain =1 (3-11)
cot β 2t

It can be seen from the above equation that the inter-meshing rotors of screw
compressors have the same helix angle on the
surface of pitch cylinder.

3.1.3 Normal to the Helical Surface

As shown in Fig 3-3, suppose T, n are

the respective tangent and normal of point M on
segment c. The projection of vector n of any
point on the curve in the coordinate system can
be expressed as

Fig 3-3 Tangent and Normal

59
 ∂y
nx = −
∂t
(3-12)
∂x
ny =
∂t

In order to get the vector n of the

normal of any point M on curved surface S
expressed by (3-1), a series of coordinate
curves can be made on the curved surface S as
in Fig 3-4. Now set a value for the constant, for
example, name t=constant, a group of spatial
curves on the curved surface S are obtained,
called τ curves. Obviously, on τ curve,
t=constant, only the parameter τ changes; in the
same way, curve t that τ curve crosses can be
decided, in t curve, τ =constant, only parameter
t changes. These two curves intersected form a
curved surface S.

Fig 3-4 Normal to Curved Surface

The curved surface S can be expressed with vector r [x (t, r), y (t, τ), x (t, τ)].
∂r
In curve t (τ does not change), the variation ratio of t along the curve at point M
∂t
stands for a tangent touching curve t at point M; similarly, in τ curve (t doesn’t
∂r
change), the variation ratio of τ along the curve at point M stands for a tangent
∂τ
∂r
touching curve τ at point M. And the planes determined by the two tangents and
∂t
∂r
is the tangent plane of the curved surface S at point M, and perpendicular line to
∂τ
this tangent plane is the normal n of the curved surface S at point M, i.e.

i j k
∂r ∂r ∂x ∂y ∂z
n= × =
∂t ∂τ ∂t dt ∂t
∂x ∂y ∂z
∂τ ∂τ ∂τ

The projection of normal vector in every coordinate axis is

60
 ∂y ∂z ∂z ∂x ∂x ∂y
∂t ∂t ∂t ∂t ∂t ∂t
nx = ny = nz = (3-13)
∂y ∂z ∂z ∂x ∂x ∂y
∂τ ∂τ ∂τ ∂τ ∂τ ∂τ

Derive the partial derivative in this equation to obtain the component of the
normal vector of (3-2) for the right helical convolute, that is:

∂x ∂x0 ∂y ∂x
= cos τ − 0 sin τ = − x0 sin τ − y 0 cos τ = − y
∂t ∂t ∂t ∂τ

∂y ∂x0 ∂y ∂y
= sin τ + 0 cos τ = x0 cos τ − y 0 sin τ = x
∂t ∂t ∂t ∂τ

∂z ∂z
=0 =p
∂t ∂τ

Substituting the above equations into (3-13), thus obtaining the component of
the normal as

∂y
nx = p
∂t
∂x
ny = − p (3-14)
∂t
∂x ∂y
nz = x + y
∂t ∂t

∂y
nx = p
∂t
∂x
Or ny = − p (3-15)
∂t
1 ∂( x 2 + y 2 )
nz =
2 ∂t

By the same way, the component of normal vector of the (3-3) for left helical
convolute as

61
 ∂y
nx = p
∂t
∂x
ny = − p (3-16)
∂t
1 ∂( x 2 + y 2 )
nz = −
2 ∂t

3.2 Contact Line

The contact line between the rotors of twin screw compressors is the line of
intersection of the two conjugate flanks during the meshing of two rotors. Its length
has a significant effect on the thermodynamic performance of screw compressors.
This is because the contact line is to seal the primitive closed spaces in compression
or discharge process and that in suction process. The result of research shows that in
every leakage of twin screw compressors, the leakage through contact line covers the
majority. Moreover, the shape of contact line also affects the moment distribution of
the screw rotors and shaft load. Therefore, the accurate calculation of the contact line
is an important aspect in the research on twin screw compressors.

The calculation of the contact line between the rotors of twin screw
compressors differs with the purposes of research, however, it can be summarized to
include the following three ways:

1) Calculate the total length of the contact line between the rotors. This is an
important index deciding the quality of rotor end profiles, and it is also an absolute
necessary calculation item in the research and development of new profiles.

2) Calculate the variation related to the intersection angle of rotors by the

length of contact line inside the inter-tooth space. This is a compulsory variation
correlation applied in the computer simulation and the performance evaluation of twin
screw compressors. The failure of correcting the variation correlation will affect the
calculation of gas leakage, further declining the liability of simulation and predicted
consequences.

3) Calculate the projection of contact line in one inter-tooth space on the

coordinate plane, at different intersection angles. This is the foundation and
precondition of calculating the shaft load and the moment distribution between rotors
accurately.

62
3.2.1 Relative Speed

1. The Expression of Relative Speed in Coordinate System for Male Rotor

Still applying the coordinate system in Fig 2-2, in order to get the projection of
the relative speed in the moving coordinate system O1x1y1 for male rotor, the
expression of this speed in the static coordinate system O1X1Y1 for male rotor shall be
obtained first. In the coordinate system shown as Fig 3-2, same angular velocity
− ω 2 is added to the two rotors, however, the mutual movement of the two rotors
does not change, but at this time, the female rotor remain still, and the male rotor is
performing the combined motion, i.e. bulk motion at − ω 2 and relative motion at
ω.1
According to dynamics, when a point starts combined motion, its absolute
velocity is equal to the vector sum of bulk motion velocity ve and relative speed vr, i.e.

v = v e + v t = (− ω 2) re + ω1 r1 (3-17)

In static coordinate system O1X1Y1, every vector is expressed as

r1 = X 1i + Y1 j + Z 1 k O1O2 = Ai

re = r1 − O1O2 = ( X 1 − A) i + Y1 j + Z 1 k

Suppose ω1 is specified to be one unit for, i.e.| ω1 | = 1 rad/s, which does not
affect the direction of relative speed v of the male and female rotors.

Then ω 1
=k - ω 2 = ik

Substituting all the above equations into (3-17), as

i j k i j k
v= o 0 i + 0 0 1
X 1 − A Y1 Z 1 X 1 Y1 Z1
= −(i + 1)Y1i + [(i + 1) X 1 − iA] j

63
 v X1
= − kY1
i.e. v Y1
= kX 1 − iA (3-18)

v Z1
=0

The above equation expresses the projection of the relative speed v of rotor
caused by the vector of angular velocity (| ω1 | = 1 rad/s) in every coordinate axis in
coordinate system O1X1Y1. If | ω|
1
1 rad/s, then it can be obtained by multiplying
(3-18) with | ω |.
1

The exchange of coordinates can convert the projection of v in static

coordinate system O1X1Y1Z1 into that in moving coordinate system O1x1y1z1. As for
the coordinate system in Fig 3-2, on the basis of (2-2) comes

v x1
= v X 1 cos ϕ1 − vY 1 sin ϕ1

v y1
= v X 1 sin ϕ1 + vY 1 cos ϕ1

v z1
= vZ 1

Substituting (3-18) into the above equation for

v x1
= − kY1 cos ϕ1 − kX 1 sin ϕ1 + iA sin ϕ1

v y1
= − kY1 sin ϕ1 + kX 1 cos ϕ1 − iA cos ϕ1 (3-19)

v z1
=0

In particular, X1, Y1 in above equation are the expressions of the equation for
helical convolute of male rotor in static coordinate system O1X1Y1Z1 , in order to
apply (3-2) and (3-3) for helical surface in moving coordinate system O1X1Y1Z1,
another transformation of the coordinates is required. According to (2-2), the
correlation between the moving and static coordinate systems is

X 1 = x1 cos ϕ1 + y1 sin ϕ1
Y1 = − x1 sin ϕ1 + y1 cos ϕ1
Z 1 = z1

Substituting the above equation into (3-19) to obtain the expression of relative speed
in the moving coordinate system for male rotor as

64
 v x1
= − ky1 + iA sin ϕ1

v y1
= kx1 − iA cos ϕ1 (3-20)

v z1
=0

2. Expression of Relative Speed in Coordinate System for Female Rotor

Here Fig 3-2 is still applied. In order to get the projection of relative speed in
the moving coordinate system O2x2y2z2 for female rotor, it is necessary to obtain its
equation in the static coordinate system for female rotor. Therefore, in the coordinate
system shown in Fig 3-2, the same angular velocity - ω1 is added to the two rotors,
the relative motion between the rotors remain unchanged, but the male rotor stops,
and the female rotor conducts the combined motion, i.e. bulk motion at - ω1 round
axis Z1, and relative motion at ω 2 round axis Z2. According to dynamics, when a
point carries out bulk motion, its absolute velocity is equal to the vector sum of bulk
motion velocity ve and relative speed vr, i.e.

v = v e + v r = (-ω1 ) re + ω2 r2 (3-21)

In static coordinate system O2X2Y2Z2, every vector can be expressed as

r2 = X 2i + Y2 j + Z 2 k O2O1 = Ai

re = r2 − O2O1 = ( X 2 − A) i + Y2 j + Z 2 k

Specifying ω1 to be one unit, i.e. | ω1 |=1rad/s, which does not affect the
direction of the relative speed of the male and female rotors, then

ω1 = k - ω 2 = iω1 = ik

i j k i j k
v= 0 0 1 + 0 0 i
X 2 − A Y2 Z2 X 2 Y2 Z2
= −(i + 1)Y2 i + [(i + 1) X 2 − A] j

v x2
= − kY2
i.e. v y2
= kX 2 − A (3-22)

v z2
=0

65
 The above equation is the expression of projection of the relative speed v of
rotor caused by the vector of angular velocity (| ω1 |=1 rad/s) in every coordinate axis
in coordinate system O2X2Y2Z2. If | ω1 | 1 rad/s, then it can be obtained by multiplying
(3-22) with | ω1 |.

The exchange of the coordinates can convert the projection of v in static

coordinate system O2X2Y2Z2 into that in moving coordinate system O2x2y2z2. The
corresponding coordinates with respect to Fig 3-2 includes

v x2
= v X 2 cos ϕ 2 − vY 2 sin ϕ 2

v y2
= v X 2 sin ϕ 2 + vY 2 cos ϕ 2

v z2
= vZ 2

Substituting (3-22) into the above equation for

v x2
= − kY2 cos ϕ 2 − kX 2 sin ϕ 2 + iA sin ϕ 2

v y2
= − kY2 sin ϕ 2 + kX 2 cos ϕ 2 − iA cos ϕ 2 (3-23)

v z2
=0

X2, Y2 in above equation are the expressions of the equation for helical
convolute of female rotor in static coordinate system O2X2Y2Z2, in order to apply (3-2)
and (3-3) for helical surface in moving coordinate system O2x2y2z2, another
transformation of the coordinates is required. According to (2-3), the correlation
between the moving and static coordinate systems is

X 2 = x 2 cos ϕ 2 + y 2 sin ϕ 2
Y2 = − x 2 sin ϕ 2 + y 2 cos ϕ 2
Z 2 = z2

Substituting the above equation into (3-23) to obtain the expression of relative
speed in the moving coordinate system for female rotor as

v x2
= − ky 2 + A sin ϕ 2

v y2
= kx 2 − A cos ϕ 2 (3-24)

v z2
=0

66
3.2.2 Meshing Conditions

When two rotors mesh, one helical surface of the rotor envelopes that of the
other rotor, at the contact point where the two teeth inter-envelope, there is a common
tangent surface or common normal. The so-called meshing refers that the helical
surfaces of the two rotors in relative motion can only slip mutually, instead of mutual
impacting or deviation, that is to say the normal direction relative speed should be
zero, for which, the condition is: the projection of vector v of relative speed between
the contact points of the two rotors, is zero on the common normal n of the contact
point, i.e. v n. The mathematical equation expressing that the two vectors are
perpendicular is

v•n = 0 (3-25)

Converted into projection equation v x n x + v y n y + v z n z = 0 (3-26)

Such is the condition for the meshing of the helical surfaces of the male and
female rotors, called meshing condition, whose mathematical expression is also called
meshing conditional expression.

The meshing conditional expression can be expressed in different coordinate

systems, as for those screw compressors whose axes are paralleled, there is no relative
motion in axis Z direction, hence comes the expressions of the meshing conditional
expression in the coordinate systems for male and female rotors,

Female rotor vx 2 nx 2 + v y n y = 0 (3-27)

2 2

Male rotor vx 1 nx 1 + v y n y = 0 (3-28)

1 1

In the above two equations, vx2, vy2 and vx1, vy1 represent respectively the
projection of relative speeds in moving coordinate system O2x2y2z2 and O1x1y1z1,
determined by (3-24) and (3-20); nx2, ny2 and nx1, ny1 stands for the projection of the
normal vector of the helical surface of the male and female rotors in the moving
coordinate system O2x2y2z2 and O1x1y1z1, determined by (3-15) or (3-16);

If the equation for the helical surface of female rotor is,

x 2 = x 2 (t ,τ )
y 2 = y 2 (t ,τ ) (3-29)
z 2 = z 2 (t ,τ )

Substituting (3-24) and (3-15) into (3-27) to obtain its meshing conditional expression
as

67
 ∂y 2 ∂x
(−ky 2 + A sin ϕ 2 ) p 2 − (kx 2 − A cos ϕ 2 ) p 2 2 = 0 (3-30)
∂t ∂t

Similarly, If the equation for the helical surface of male rotor is

x1 = x1 (t ,τ )
y1 = y1 (t ,τ ) (3-31)
z1 = z1 (t ,τ )

Substituting (3-20) and (3-15) into (3-28) to obtain its meshing conditional expression
as

∂y1 ∂x
(−ky1 + iA sin ϕ1 ) p1 − (kx1 − iA cos ϕ1 ) p1 1 = 0 (3-32)
∂t ∂t

It can be know form (3-30) and (3-32) that the meshing conditional
expression is an implicit function f(t, τ, ϕ )=0 or f(t, τ, ϕ )=0 that contains three
2 1

parameters as (t, τ, ϕ ) or (t, τ, ϕ ). If ϕ or ϕ is given, numerous (t, τ) can be

2 1 2 1

obtained according to meshing conditional expression, and substitute (t, τ) to

rotor tooth surface equation (3-29) or (3-31) to obtain one contact line of two
rotor tooth surfaces at position ϕ or ϕ . Therefore the meaning of meshing
2 1
conditional expression relies on that the position of contact line of rotor tooth
surfaces, which is same as the tangent conditions as introduced above while
deriving the conjugate curve or meshing line of rotor profile.

3.2.3 Equations for Contact Line

Combining meshing conditional expression and equation of rotor helical

surface can obtain the equation for contact line of make and female rotors.
Therefore, when the equation for contact line is established, it is primary to
establish the equations of every segment for rotor end profile and derive the
equation for helical curve formed by every segment. Then specific meshing
conditional expression corresponding to every segment can be derived according
to the equation for tooth surface.

Through deriving the equations for contact line, it is available to obtain

the coordinates of every spatial point on contact line at different intersection
angles. But these coordinates represent as in moving coordinate system O1x1y1z1
or O2x2y2z2. As it is very immediate to express the contact line in static
coordinate system, and in the calculation of forces on rotor, it is also required to
project contact line on the specialized plane in static coordinate system, the
coordinates of these points in static coordinate system shall be derived also.

68
 Note that when the intersection angle of rotor is zero, moving coordinate
system and static coordinate system coincide with each other, i.e. at this position,
the coordinate of contact line in moving coordinate system is also that in static
coordinate system. so the equations for contact line in static coordinate system
and the coordinate of every point on contact line in static coordinate system can
be obtained first when ϕ =0, and then different methods can be adopted to
obtain the position of contact line in static coordinate system at different
intersection angle.

3.2.4 Calculation of Contact Line

1. Derivation of Equations for Contact Line

A series of different value of t within the variation range of parametric

variable of segments of rotor profile shall be selected when equation for contact
line is to be derived, and a series of corresponding to parameter t can be
obtained according to the meshing conditional expression when intersection
angle of rotor is zero and finally coordinates of every spatial point on contact
line corresponding to t and can be obtained respectively. Thus, when parametric
variable t of segments changes for the start point to the end point, only to obtain
the helical surface formed by every segment when rotor intersection angle is zero
and the coordinate of its conjugate curve in static coordinate system and
furthermore the projection of every point on contact line on different coordinate
planes. Fig 3-5, 3-6 and 3-7 show the typical calculated result of certain profile,
and the projection of contact line in Fig 3-5 on plane O2X2Y2 is the meshing line
of rotor profile previously described.

69
 Fig 3-5 Projection of Contact Line on Plane O2X2Y2

Fig 3-6 Projection of Contact Line on Plane O2X2Y2

Fig 3-7 Projection of Contact Line on Plane O2X2Y2

2. Length of Contact Line in One Inter-tooth Axial Pitch

The calculation of the length of contact line in one inter-tooth axial pitch
between meshing rotors can integrate the equations for contact line in segments.
Although this method can obtain the accurate value for the length of contact line,
complicated derivation of equations is required to be carried out.

Since spatial coordinate of every point on contact line through deriving equations for
contact line, the length of contact line can also be known.

70
 Fig 3-6 Fig3-7

Specifically, while establishing the equations for contact line, distribute the
contact line in one inter-tooth axial pitch for N number of points, and then the length
of the contact line in one inter-tooth axial pitch is

lj = i =2
( X i − X i −1 ) 2 + (Yi − Yi −1 ) 2 + ( Z i − Z i −1 ) 2 (3-33)

When the above equation is applied, more points are calculated, the more
accurate it will be.

3. Calculation of the Total Length of Contact Line between Rotors

When torsion angle τ2z(τ1z) of female (male) rotor is not equal to the integral
multiple of 2 /z2 (2 /z1), the total length of contact line during operation keeps
changing, but owing to the high variation frequency, normally adopt and average to
calculate, expressed as

τ 2z
l= z 2l j (3-34)
2π

4. The Change of the Length of Contact Line in Inter-tooth Space with the
Intersection Angle

In the computer simulation and performance evaluation of working process of

screw compressors, it is required to provide the change of the length of contact line in
the discussed inter-tooth space with the intersection angle so as to obtain the leakage
at different intersection angles. There are many ways to get this variation correlation,
here only a simple and accurate calculation method is introduced.

71
 Once the contact line inside the space is formed, its shape shall not change and
only moves paralleled in the axial direction. According to this characteristic of contact
line, it can be understood that there is one invented contact line on the exterior of the
suction port entering gradually the effective domain of rotor. The disappearance of
contact line can be understood that the contact line moves gradually out of the
discharge port from the effective domain of rotor. On the basis of the above thoughts,
the calculation of primitive space against the change of the length of contact line with
the intersection angle or male rotor.

Fig 3-8 Contact Line in One Inter-tooth Space

1) As shown in Fig 3-6, translate sect 15 in the contact line of one axial pitch
along axis Z2 for a range of T2/z2, hence comes the shape in Fig 3-8, this is the shape
of contact line in one space.

2) Subtract the coordinate Z2 of every point on all contact lines with a

constant,

3) Obtaining the result as in Fig 3-9a, i.e. move the contact line outside the
effective domain of the corresponding rotor at 0°with the intersection angle of male
rotor.

4) Correspond different intersection angle ϕ of male rotor, increase

1

coordinate Z2 of each point on the contact line by T1 ϕ /2 , and calculate only the
1
length of the contact line in the effective domain of rotor (as solid line in the figure),
thus obtaining the length of the contact lines in the space at different intersection
angle (Fig 3-9).

72
 Fig 3-9 Calculation of Length of Contact Line at Different Intersection Angle

Finally, obtain the change of the length of contact line in the inter-tooth space with the
intersection angle shown in Fig 3-10.

5. Projection of Contact Line on the Given Coordinate Plane

Adopting the same method as in Fig 3-9, translate each point on contact line
along axis Z2, hence obtaining the coordinate for every point on the contact line at
different intersection angle, then as in Fig 3-6, Fig 3-7, and then project these points
on the given coordinate plane, thus coming the related area values of the section of
contact area exerted with different pressure inside the inter-tooth space, which lays

73
the foundation for the accurate calculation of moment distribution between the shaft
load and rotors.

Fig 3-10 Variation of Length of Contact Line with Intersection Angle of Male Rotor

3.3 Blow-hole Area

When the contact line between male and female rotors of screw compressors fails to
reach the intersection line between the two cylinder holes on the housing, it will cause
leaking blowhole area shown as in Fig 3-11. It is necessary to point out that the
blowhole exists not only in compression side of compressors but also in the suction
side, and the blowhole area in the suction area is far bigger than that in the
compression side. As in majority of the inter-tooth spaces in the suction side, there is
no differential pressure, thus the blowhole area in suction side has a minor effect on
the efficiency and leakage of compressors. Here, mainly discuss the blowhole area in
the compression side.

74
 Fig 3-11 Blowhole Area

As shown in Fig 3-11, the blowhole area is a spatial triangle with curved
edges. Its vertexes are: the vertex 1 of the contact line between the male and female
rotors, vertex 2 between female addendum and the intersection line of two cylinder
holes, vertex 3 between male addendum and the intersection line between two
cylinder holes.

Steps to calculate the blowhole area are as following:

1) Obtain the coordinate of vertex 1 of contact line through deriving the

equation for contact line between rotors, and then establish the straight-line equation
for the intersection line of two cylinder holes.

2) Establish the equation for the plane formed between the intersection line of
two cylinder holes and vertex 1 of the contact line.

3) Combine the equation of this plane with the equations for the helical
surfaces of female and male rotors separately, thus obtaining the equation of the two
curved edges of the blowhole.

4) Applying these two equations of straight-line equations of curved edges and

the straight-line equation of the intersection line of the cylinder holes, and then
calculate the blowhole area with the method of curvilinear integral.

75
 Of course, another method can derive the coordinates of every point in
blowhole and then calculate its area by means of numerical integration.

Note that the area calculated through above steps is the one in the plane
formed between the intersection line of two cylinder holes and vertex 1 of contact
line, as a matter of fact, the area perpendicular to the fluid streamline is the main
factor that affects the leakage. Accordingly, the streamline of blowhole can be
considered as the helix whose axis is that of female rotor, whose helical performance
number is also that of female rotor. Therefore, the blowhole area which is crucial to
leakage can only be ultimately obtained through projecting the blowhole area derived
from the above steps on the normal plane of the streamline.

3.4 Contact Line and Blow-hole Area of Typical Rotor Profiles

Dissimilitude some typical rotor profiles through the common methods for
deriving contact line and blowhole area as mentioned before. Fig 3-12 shows the
results of symmetrical circular arc based profile (1), SRM-A profile (2), SRM-D
profile (3). It can be seen from the figure the blowhole areas of asymmetric SRM-A
profile and SRM-D profile are obviously smaller than that of symmetrical profile.
Meanwhile the length of contact lines of these two asymmetric profiles increase
unavoidably, which implies that only with small meshing gaps or sufficient sealing oil
can the screw compressors with asymmetric profiles have advanced performance.

Fig 3-12 Comparison between Double Side Symmetrical Circular Arc Based Profiles
(1) , SRM-A Profiles (2) and SRM-D Profiles (3)

a) contact line and blowhole area b) enlarged drawing of blowhole area

Fig 3-13 shows the results of single side cycloid-pintooth circular arc based
profile (1) and Atlas-X profile (2). It can be seen from the figure that there is no much
difference between these two types of profile. Atlas-X profile adopts rather long
straight line segment at the high-pressure side of the female rotor, thus causing the

76
bigger blowhole area. However, the radius of the tooth depth in Atlas-X is bigger,
which leads to the shorter contact line, so it is with rather good performance.

Fig 3-13 Comparison between Single Side Cycloid-Pintooth Circular Arc Based
Profile (1) and Atlas-X Profile (2) a) contact line and blowhole area
b) enlarged drawing of blowhole area

1) single side cycloid-pintooth circular arc based profile 2) Atlas-X profile

Fig 3-14 shows the results of GHH profile and Fusheng Profile. In this figure,
although Fusheng profile has rather big blowhole area, its contact line at low-pressure
side has very good shape, which is favorable to form oil film and improve the
meshing performance of rotors.

Fig 3-14 Comparison between GHH Profile and Fusheng Profile a) contact line and
blowhole area b) enlarged drawing of blowhole area

77
3.5 Rotor Inter-tooth Area and the Area Coefficient

3.5.1 Rotor Inter-tooth Area

The area between male and female rotor is one of the major geometric
characteristics of screw compressors, after establishing the equations for segments of
rotor profile and decide the parametric variation range, obtain the area between rotors
through analytic method.

As shown in Fig 3-15, if the parametric equation of segment AB and its

variation range is

x = x(t )
t a ≤ t ≤ tb
y = y (t )

Then area enclosed by segment AB, OA and OB is

Fig 3-15 Calculation of Inter-tooth Area

A=
1 tb dy (t) i
x− dx (t)i
y dt (3-35)
2 ta dt dt

The above equation is the basic correlation for calculating inter-tooth area. As
the area is formed by several segments and both ends of addendum circular arcs, the
area can usually be expressed as

i
1 t i +1 dy (t) dx (t) y
A=
1 2 ti dt
i
x−
i
dt
i
i
dt (3-36)

78
 Where xi=xi(t), yi=yi(t) and d(xi)=dxi(t)/dt, d(yi)=dyi(t)/dt are the parametric
equations of segments (including the supplementary addendum circular arcs) in sect i
and the derivatives of the parameters; ti, ti+1 are the parameters of the start point and
end point of segment (including the supplementary addendum circular arcs) in sect i.

According to (3-36), area A02, A01 between the male and female rotors are
expressed respectively as

i
1 t i +1 dy (t) dx (t)
A02 =
2 ti
2i
dt x 2i
−
dt
2i
y 2i
dt (3-37)
1

i
1 t i +1 dy (t) dx (t)
A01 =
2 ti
1i
dt x 1i
−
dt
1i
y
1i
dt (3-38)
1

3.5.2 Area Coefficient

The area utilization factor of screw compressors stands for the utilization
extent of the total area in the domain of rotor diameter. Its definition equation is

z1 ( A01 + A02 )
Cn1 = (3-39)
D12

Where Cn1—is the area utilization factor for screw compressors;

z1—is the number of male rotor teeth;

D1—is the diameter of male rotor

Obviously, the area utilization factor Cn1 is determined by rotor profile types,
radius of tooth depth, number of teeth, addendum etc. Area utilization factors of some
commonly used profiles are give in Tab 3-1.

Tab 3-1 Profile constants of commonly used profiles

Rotor Double Single side Atlas- SRM- GHH Fusheng SRM-D Hitachi
profile side asymmetric X A profile Profile profile profile
circular cycloid- profile profile
arc pintooth
based circular arc
profile based profile
Profile 0.4889 0.4696 0.4856 0.5009 0.4495 0.4474 0.4979 0.4013
constant

79
3.6 Volume Changes of Rotor Inter-tooth Space and the Process

3.6.1 Rotor Inter-tooth Space

After obtaining the inter-tootharea based on rotor profiles, the inter-tooth

space can also be derived easily. In general, suppose the inter-tooth area is A, the
length of effective working section is L, then the space V is

L L
V= dV = Adz = AL (3-40)
0 0

Obtaining from above equation for the inter-tooth space V01, V02, respectively
expressed as

V02 = A02 L (3-41)

V01 = A01 L (3-42)

3.6.2 Volume Changes of the Space

During the operation of screw compressors, the inter-tooth space always

decreases because the encroachment of the rotor teeth, hence resulting in the
compression of the gas. The study on the variation law of the volume change is the
base to calculate gas pressure increase process inside the screw compressors and
design the suction and discharge ports. This change in volume, if described with the
change of the area change between rotor end planes, can transform the complicated
space problem into plane problem.

As shown in Fig 3-16, when female rotor tooth 1’ rotates to area A01 where it is ready
to encroach male rotor tooth 1, i.e. the start point of compression, as well as

Fig 3-16 Rotor position where primitive space starts to reduce

80
the start point where the space begins to reduce, the diameter of addendum of the
corresponding male rotor tooth 1 and connection line O1O2 forms an inclination .

Specify that the intersection angle of male rotor at this position is zero, i.e.
ϕ 1
=0. Subsequently, the inter-tooth area after male rotor tooth 1 reduces gradually
from maximum because of the encroachment of female rotor tooth 1’.

From the start point of compression process, adopt analytic method, numerical
integration or graphic integration according to the equations for rotor profiles and
fiducial mark of profiles, to obtain the variation curve (Fig 3-17a) formed by the inter-
tooth area A1r that is created while male rotor tooth encroached by female rotor tooth,
rotating with the intersection angle of male rotor. Similarly, obtain the variation curve
(Fig 3-17b), formed by the area A2r that is created while female rotor tooth
encroached by male rotor tooth, rotating with the intersection angle of male rotor. It
is obvious that where the inter-tooth area of female rotor starts to decrease is one
angle lag behind. Superpose Fig 3-17a and Fig 3-17b to get Fig 3-17c, which explains
the relation that the encroachment value Ar changes with intersection angle ϕ .
1

In Fig 3-17, τ1z is the torsion angle or wrap angle of male rotor, standing for
the angle that male rotor profile performs helical motion from one end plane of rotor
to the other end plane, and

81
 Fig 3-17 Inter-tooth Area is Encroached
a) inter-tooth area of male rotor is encroached
b) inter-tooth area of female rotor is encroached
c) a pair of inter-tooth area is encroached <Line>
2π
ϕ1k = β + (3-43)
z1

The reduced value caused by the mutual encroachment of the areas of screw
compressors can be obtained by the area under curve Ar- ϕ as shown in Fig 3-17c,
1
i.e.

T1 ϕ1
Vr = Vr (ϕ1 ) = Ar (ϕ )dϕ (3-44)
2π 0

According to (3-44), the correlation curve formed by the reduced values and
intersection angle ϕ as shown in Fig 3-18.
1

82
 The curve Ar- ϕ 1
in Fig 3-17c and curve Vr- ϕ 1
in Fig 3-18 can be divided
into three phases.

1) Phase I (0 ϕ ϕ 1 1k
) This phase starts from when the inter-tooth space
begins to reduce, till the process when the female rotor teeth completely sweeps the
inter-tooth area on the suction end plane, i.e. till the contact line whose shape and
length does not change is formed in the inter-tooth space of the male and female
rotors. The exact value of ϕ is determined by profile types, number of teeth of the
1k
male and female rotors etc.

In this phase, the reduced value V1r in the space, if functional expression
Ar ( ϕ ) is know, can be obtained through integration method on the basis of (3-44); if
1

the curve Ar( ϕ )- ϕ has been presented according to numerical integration or

1 1
graphic integration, it can be expressed by multiplying the area below the curve
within a certain range with T1/2 . For example, the first phase ends, i.e. ϕ = ϕ ,
1 1k
the reduced value of the volume should be V1k=S0T1/2 (refer to Fig 3-17c).

Fig.3.18

2) Phase II ( ϕ ϕ τ1z) This phase starts from the end of the first phase
1k 1

till the male rotor rotates for a torsion angle τ1z . The reduction of the volume in this

83
phase can be understood that it is caused by the propulsion of the contact line formed
at intersection angle ϕ towards the discharge end. Therefore, the reduced value in
1k
volume is proportional to intersection angle, deriving from Eq (3-44) to obtain

T1 ϕ1 T1
V2 r = A0 dϕ = A0 (ϕ1 − ϕ1k ) (3-45)
2π ϕ1 k 2π

Plus the reduced value V1k in phase I, the total reduced value can be expressed
as

T1
Vr = V1k + V2 r = [ S 0 + A0 (ϕ1 − ϕ1k )] (3-46)
2π

When ϕ = τ1z , according to (3-46), the following can be obtained

1

T1
V2 z = A0 (τ 1z − ϕ1k ) (3-47)
2π

It is obvious that when phase II ends, i.e. ϕ 1

= τ1z , the total reduced value in
inter-tooth space is

T1
V2 z = [ S 0 + A0 (ϕ1z − ϕ1k )] (3-48)
2π

3) Phase III (τ1z ϕ 1

[τ1z + ϕ ]) This phase starts from the end of phase II
1k
till relative teeth of the volume pair stop meshing. The method to determine the
reduced value V3r in this phase is similar to that in phase I. With Ar(ϕ ), it can be
1

obtained through Eq (3-44); with curve Ar( ϕ )- ϕ , it can be expressed by the area
1 1

below the curve within certain range. As shown in Fig 3-17c, when ϕ 1
= [τ1z +ϕ ],
1k
the reduced value in phase III is V3kz=S’0T1/2 . Hence comes the correlation

T1
V1k + V2 z + V3kz = [ S 0 + A0 (τ 1z − ϕ1k ) + S 0'] = V0 (3-49)
2π

It is know from the above analysis that the male rotor rotates with an angle
[τ1z + ϕ ] while the male and female rotors of screw compressors start meshing till
1k
the end of meshing. During this period, the space of the contact surface on one side of
the contact line reduces from maximum to zero, implementing the compression and
discharge process. In the mean time, the space on the other side the contact line
expands from zero to maximum, implementing the suction process. Suppose when the

84
space increases to maximum and then reduce immediately, then the entire change
process that the space expands from zero to maximum and then reduce to zero can be
obtained shown as in Fig 3-19.

Fig 3-19

It can be seen from Fig 3-18 and Fig 3-19, during the encroaching period
(0 ϕ 1
ϕ ) and the detaching period (τ1z ϕ [τ1z +ϕ ]) , the variance ration of
1k 1 1k
inter-tooth space differs with the intersection angles of male rotor. However, in most
of the time ( ϕ ϕ τ1z), the variance ration remains same, the increase or reduction
1k 1
of the inter-tooth space has a linear relation with the intersection angle of male rotor,
which resulting in the stable rise pressure, and uniform suction or discharge flow.

3.7 Filling factor and Built-in Volume Ratio

3.7.1 Filling factor

If the inter-tooth area of the female rotor and male rotor is respectively A01,
A02, and the length of effective working section of rotor is L, then the maximum value
Vmax of the space is

Vmax = A01 L + A02 L (3-50)

As introduced previously, the two rotors of screw compressors mesh from

suction end and detach at discharge end, the male rotor needs to rotate an angle of

85
[τ1z + ϕ ] . During this period, the space increases from zero to maximum as shown
1k
in Eq (3-50). However, on the other hand, as shown in Fig 3-16, when male rotor
tooth 1 rotates from the position in the figure for an angle of 2 , the inter-tooth area
after that shall be encroached again on the suction end plane. According to the above
analysis, if [τ1z + ϕ ] <2 , the space will not start to reduce immediately after
1k
increasing to maximum expressed in Eq (3-50), as the curve 2 shown in Fig 3-20.
However, if [τ1z + ϕ ] >2 , before the inter-meshing rotors detach with each other
1k
completely at the discharge end, the meshing starts again at the suction end, i.e. the
extrication and encroachment of the inter-tooth space happens simultaneously, as
curve 3 in Fig 3-20.

Fig 3-20 Influence of torsion or wrap angle relative to volume change

1 → [τ 1z + ϕ1k ] < 2π ; 2 → [τ 1z + ϕ1k ] = 2π ; 3 → [τ 1z + ϕ1k ] > 2π

As curve 3 shown in Fig 3-20, the inter-tooth space can not finish air inflation
completely, impossible to reach the maximum expressed in (3-50). With this taken
into account, torsion angle coefficient C ϕ is applied to express the ratio between the
maximum space V0 that the space can reach and Vmax, i.e.

V0
Cϕ = V max
(3-51)

In screw compressors, if the torsion or wrap angle of rotor is too small, it will
deteriorate the performances of compressors; if the torsion angle is too big, it will lead
to very small coefficient. The torsion or wrap angle of male rotor ranges from
250°~300°, in which the coefficient normally is 0.97-1.0, Tab 3-2 has listed the
coefficients of common profiles at different torsion angles.

86
 Tab 3-2 Filling factor of Common Profiles

Torsion Double side Single side SRM- GHH SRM-D Hitachi

or wrap symmetrical asymmetric A profile profile profile
angle of circular arc cycloid-pintooth
male based profile circular arc based profile
rotor profile

240° 1.0 0.9989 0.9992 1.0 0.9995 1.0

270° 0.996 0.9905 0.9907 0.9976 0.9916 0.9987

300° 0.9769 0.971 0.9711 0.9841 0.9726 0.987

87
3.7.2 Built-in Volume Ratio

The built-in volume ratio is a major geometric characteristic of screw

compressors, which decides the position of suction port and can also have a
significant effect on the performances of compressors. It is defined as

V0 V0
ε v
= =
Vi Vmax − Vr
(3-52)

Where Vi——is the volume value when inter-tooth space connects the suction
port, i.e. the value at the end of suction process;

Vr——is reduced volume value of inter-tooth space during

compression process.

In screw compressors, the compression process of gas usually stops in phase

II, as shown in Fig 3-17 and Fig 3-18. It might end in phase I when the pressure is too
low or working as a blower. Phase III is always the discharge process, otherwise the
design of the discharge port will be a problem.

As for the screw compressors whose compression process ends in phase II, the
built-in volume ratio can be obtained by substituting (0 ϕ ϕ )
1 1k

v = C ϕ A τ T2π
0 0 1z
1
and Eq (3-46) into Eq (3-52) for

V0 Cϕτ 1z
ε v
= =
Vi τ − ϕ + ϕ − S0
(3-53)
1z 1c 1k
A0

In which, ϕ1c——is the internal compression intersection angle of male rotor,

standing for the intersection angle of male rotor at the moment when the inter-tooth
space connects discharge port.

The built-in volume ratio of the machine can be obtained from (3-53) so as to
test the feasibility of the operation of the machine. On the contrary, when the machine
is designed, the internal compression intersection angle ϕ1c or male rotor can be
decided according to the desired built-in volume ratio. Thus convert (3-53) for

88
 Cϕ S0
ϕ1c = τ 1z 1 − + ϕ1k − (3-54)
εV A0

In approximate calculation, phase I, when the inter-tooth area encroaches

curve can be considered to be line ab as shown in Fig 3-21.
As in Fig 3-21 showing the simplified assumption, if the compression process
of gas stops in phase I (0 ϕ ϕ ), as
1 1k

T1 ϕ1 c T1 ϕ1 c A0ϕ T1 A0 ϕ12c
Vr = ( Ar (ϕ )dϕ = dϕ = (3-55)
2π 0 2π 0 ϕ1k 2π ϕ1k 2

Substituting the above equation into (3-52) to obtain

Cϕτ 1z
ε v
=
1 ϕ12c
(3-56)
τ 1z −
2 ϕ1k

If the compression process of gas stops in phase II ( ϕ ϕ τ1z), then

1k 1

1 1
S 0 = ϕ1k ( A01 + A02 ) = ϕ1k A0
2 2

Fig 3-21 Encroachment by Inter-tooth Area in Phase I and Its Changes

Substituting the above equation into (3-53) and (3-54) to obtain

Cϕτ 1z
ε v
=−
1
(3-57)
τ 1 − ϕ1c + ϕ1k
2

89
 Cϕ 1
And ϕ1c = τ 1z 1 − + ϕ1k (3-58)
εv 2

It can been know from (3-57), the built-in volume ratio v of screw
compressors has relation with the torsion angle τ1z, built-in compression intersection
angle ϕ1c and the intersection angle ϕ in phase I. Therefore, built-in volume ratio
1k
can be increased through the following methods:

1) Reduce the intersection angle ϕ in phase I It can be seen from (3-

1k

43), the main factor that affects the value of ϕ is the number of teeth z1. The
1k

increase of the number of teeth can sharp drop ϕ . This is why multiplex rotor teeth
1k
have been applied in the machines with high built-in volume ratio. If the differential
pressure of the compressors at this time is too big, the number increase of rotor teeth
can also benefit the flexibility of rotors.

2) Increase the built-in compression intersection angle ϕ1c as introduced

earlier, normally the built-in compression process shall end in phase II. It is necessary
to mention that over increase angle ϕ1c always cause some difficulties for the
structural design of suction port, meanwhile it also steps up the resistance loss while
the gas flow through the suction port greatly.

3) Reduce torsion angle τ1z under the same confrontation conditions, the
reduction of torsion angle shall intensify the volume change at torsion angle ϕ1c in the
same compression. However, this reduction can also result in too small suction port
which will add difficulty in the design.

3.8 Suction Port

The appropriate position and shape of the suction port of screw compressors
are the necessary for the compression process of gas. For this, when suction port is
designed, following requirements should be supplied:

1) The suction port should abate the influence towards suction closed space.

2) The position of suction port should ensure the maximum air inflation of the
inter-tooth space so as to improve the space efficiency of the machine.

3) Gas loss at the suction port and inside the inter-tooth space should be as less
as possible, that is, the port should be as big as possible and the gas bypass section
should be smooth.

90
3.8.1 Axial Suction Port

1. Suction start angle

As for the currently widely used asymmetric profiles, when the female rotor
rotates through the intersection point of the two addendum circles and meshes with
the male rotor, the inter-tooth space on one side the contact line shall reduce
gradually. On the other side of the contact line, the rotor inter-tooth space is
expanding from zero. As shown in Fig 3-22, the falcate-like wedge space V1 on the
suction end plane increase with the rotation of the rotors, but because space V2 on the
other side of the contact line is in compression process, suction port can not be
positioned in this part. This space that expands before connecting the suction port is
called air-breathing closed space, the gas inside which shall inflate and the gas
pressure shall be lower than suction pressure. However, the space in this part is not
big, besides there is rather big axial clearance on suction end plane, so as a matter of
fact, this reduction in pressure does not affect the performance of compressors much.
As for asymmetric rotor profiles, there will be different air-breathing closed spaces.

Fig 3-22 Air-breathing Closed Space

When the male rotor rotates after the connection line of the centers of two
rotors, space V2 in compression process disconnects suction end plane, suction port
can be placed from this position afterwards. It is necessary to mention that suction
port should be within the meshing line to prevent space V2 from reflowing to suction
port (Fig 3-22), because when the air-breathing closed space connects the suction
port, the gas pressure inside the space shall increase to normal suction pressure. In
order to enable the inter-tooth space start suction process early, the suction port
should be as close as possible to the connection line of the two centers.

91
 2. Suction End Angle

The position of suction port should ensure the inter-tooth space can have the
maximum air inflation, i.e. when the space expands to maximum, it will disconnect
with suction port and starts the compression process. According to this, the axial
suction angle of female rotor and male rotor can be obtained as 2s, 1s, furthermore,
the axial suction port on the suction end plane of screw compressors can be
positioned, as shown in Fig 3-23.

The axial suction angle 1s of male rotor is decide by the following

1
α 1s = 2π − ϕ1k + ∆ϕ = 2π 1 − − β + ∆ϕ (3-59)
z1

Where —— is the male rotor intersection angle when female rotor teeth encroach
the inter-tooth space of male rotor (Fig 3-16)

Fig 3-23 The Position and Shape of the Axial Suction Port on Suction End Plane

∆ϕ —— ϕ is the revised value for the suction angle of male rotor when C ϕ <1.

If [τ1z + ϕ ] 2 , then ∆ϕ =0; when [τ1z +ϕ ] k>2 , the correct value of

1k 1k

∆ϕ should be determined according to the variation rules of inter-tooth space in

Fig3-19.

92
 Suppose the encroachment and detachment of the inter-tooth space are in
symmetric relation, according to Fig 3-24, value of ∆ϕ can be obtained
approximately.

τ 1z + ϕ1k − 2π
∆ϕ =
2

2π
With ϕ1k = β + substituted into the above equation to obtain
z1

Fig 3-24 Determining the Suction Port When [τ1z + ϕ ] >2

1k

1—increase the inter-tooth space 2—reduce the inter-tooth space

3—actual inter-tooth space

τ 1s β 1
∆ϕ = + −π 1− (3-60)
2 2 z1

Once the axial suction angle of male rotor 1s is obtained, according to the
relative movement between the male and female rotors, naturally the axial suction
angle of female rotor 2s is

2π
α 2 s = iα1s + (3-61)
z2

As shown in Fig 3-25, in some situations, when the inter-tooth space of female
rotor reaches maximum, it will not start compression immediately, which shows that
the axial suction angle or female rotor is bigger than that determined by Eq (3-61), the
maximum can be derived from the following

93
 α 2 s max = 2π − δ − β 02
(3-62)
β 02 = ∠WO2 O1

Where ——is the inclination between the diameter line of slot base of female
rotor and the addendum of its front.

Fig 3-25 The Determination of Maximum Axial Suction Angle 2smax of Female Rotor

Usually the suction angle of female rotor can be calculated through Eq (3-61).
Sometimes with the actual delay of gas flow taken into account, the slightly bigger
value than that derived from Eq (3-61) is chosen appropriately, but not suitable from
Eq (3-62), this is because the heating action to gas by rotors and housing will cause
the loss of so-called ‘inlet heating’ which is unfavorable to air inflation.

After the suction angles 2s and 1s are decided, it is easy to get the axial
suction port on the end plane of screw compressors, its position and shape are shown
as in Fig 3-23.

It can be seen from Fig 3-23 that the entire axial suction ports on the suction
end plane are comprised of many segments. Segment 1-2 is the front profile behind
the inter-tooth space of male rotor, and its position is determined by 1s; Segment 3-4
should choose the shape of the meshing line at low-pressure side of the profile;
Segment 5-6 is the front profile behind the inter-tooth space of female rotor, and its
position is determined by 2s. Segment 2-3, and 4-5 can be decide by the possible
maximum flow area, standing separately for the rotor end circle of male and female
rotors. However, in order to increase the area of suction port for easy assembly,
maintenance, and reduction of noise, this part of the housing is normally hollowed
out.

94
3.8.2 Radial Suction Port

In order to expand the flow area of the suction port as big as possible, the
housing is usually hollowed out in axial direction as radial suction port while the axial
suction port is opened, as in Fig 3-26a.

The shape of the hollowed out radial suction port can be decided according to
the methods below: with the suction angle of female rotor and male rotor known as
2s, 1s , the positions of the two addendums A and B can be fixed, as well as the
corresponding helixes A1-A2-A3 and B1-B2-B3. Segment A2-A3 and B2-B3 locate
below the axial plane of two rotors. The circular helix A1-A2-A3, and B1-B2-B3 can
be determined by the diameters of female and male addendums and the lead. The
axial poison z of any point on helix is

T
z= θ (3-63)
2π

In which, —is the torsion angle starting from the radial line of addendums A and B
which rotates against the rotation of rotors. r is the lead of rotor.

In the actual design of screw compressors, some compressors only apply axial
suction port, i.e. the gas flow into the compressors paralleled with the axis of rotor.
And some others apply only the radial suction port, i.e. the gas flow into the
compressors perpendicular to the axis of rotor. But mostly the combination of axial
suction and radial suction port is adopted. The advantage for only radial suction port
is that the length of compressors can be shorter, however, the centrifugal force
occurring while the gas inside the space rotates with rotors, will affect the flow
through suction port. Research shows, when the speed of addendum is too low, the
application of radial suction port will result well, however if the speed of addendum is
too high, axial suction port will help to get a high efficiency. The advantage of the
combination of axial suction port and radial suction port is that the flow area through
the port is big, resulting in the less pressure loss. The most common used combined
suction port is based on the axial suction port, another space shall be kept at the
position of radial suction port on the casing. In some large-scale screw compressors,
the dug-in depth can be 20mm, however in some of those mini compressors, the depth
is only 5mm.

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 Discharge end

Fig 3-26 Determining the Position and Shape of Radial Suction Port

3.8.3 Axial Suction End Angles for Typical Profiles

The suction angle of screw compressors is mainly decided by profile type,

torsion angle and rotor tooth ratio. The suction angle 1s of male rotor of the common
profiles are listed in Tab 3-3.

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Tab 3-3 Suction Angle of Male Rotor of Common Profiles

Torsion Double side Single side SRM- GHH SRM-D Hitachi

or wrap symmetrical asymmetric A profile profile profile
angle of circular arc cycloid-pintooth
male based profile circular arc based profile
rotor profile

240° 255° 249° 249° 256° 249° 257°

270° 270° 265° 264° 273° 265° 273°

300° 285° 280° 279° 288° 280° 288°

3.9 Discharge Port

3.9.1 Axial Discharge Port

1. Start Angle of Discharge

The position and shape of the discharge port of screw compressors should
ensure that the gas inside the inter-tooth space prearranged built-in compression, to
enhance the economical efficiency of machines. The built-in volume ratio requires a
corresponding discharge port. That is to say, every discharge port can reach a certain
built-in volume ratio.

According to the working conditions of screw compressors, the required built-

in volume ratio can be obtained. Through the variation rules of inter-tooth space , the
built-in compression angle ϕ of male rotor and the axial discharge angle of female
1c
and male rotors as 2d and 1d corresponding to the built-in volume ratio can be
obtained.

The start angle of discharge port is decided by the suction angle 1s and the
built-in compression angle ϕ . As shown in Fig 3-27. The discharge angle 1d of
1c
male rotor is

2π
α 1d = 2π − α 1s − + τ 1z − ϕ1c (3-64)
z1

With (3-59) substituted into the above equation for

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 α 1d = β + τ 1z − ϕ1c − ∆ϕ (3-65)

The corresponding discharge angles of female rotor can be

calculated through following equation according to the principle of simultaneous
discharge by the inter-tooth spaces of male and female rotors.

Fig 3-27 The Position and Shape of the Axial Discharge Port

2π
α 2 d = α1d i + (3-66)
z2

2. End Angle of Discharge

As shown in Fig 3-28, as for the asymmetric profile, when female rotor rotates
through the intersection point of the two addendum circles, and meshes with male
rotor, the space V4 under discharge pressure on one side of the contact line reduces
gradually. While on the other side of the contact line, the space V3 under suction
pressure expands gradually.

Fig 3-28 Shape of Discharge Port

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 In order to prevent the gas under discharge pressure reflowing to space V3
under suction pressure, the suction port should not be within the extent of meshing
line (Fig 3-28). On the other hand, if inter-tooth space disconnects with discharge port
before the space V4 reduces to zero, there will be discharge closed space occurring. In
this situation, the gas pressure inside this space shall expand sharply, which results in
the increase of power consumption of the compressors and also influences the safe
operation of the machine. In order to discharge all the gas inside V4, the discharge
port should be as near as possible to the connection line of the two rotor centers, i.e.
the end angle of discharge for male rotor should be as in Fig 3-27 and in Fig 3-28 it
should be zero. It is known from the above analysis that as long as the discharge port
is designed appropriately, the asymmetric profile shall not cause the discharge closed
space.

According to 1d and 2d, the position and shape of the axial discharge port
can be decided. As shown in Fig 3-27, the line type of axial discharge port is 1-2-3-4-
5-6-7-8-1. It is necessary to mention that the segments 6-7 and 1-2 in the figure comes
respectively from the dorsal segment of the profile of the rotor teeth in front of the
space between female and male rotors; segment 3-4-5 should choose the shape of
meshing line at high-pressure side; segments 5-6 and 2-3 are the rotor root cycles of
female and male rotors and the segment 7-8-1 outside the port superposes with the
circular wall inside the cylinder, but this part of the housing is always hollowed out.

In particular, as for asymmetric profiles, in order to reduce the discharge

noise, and loss of gas flow and considering the easy manufacturing, vertex 4 of
meshing line on the discharge port of end plane is always scappled. After this, part of
the discharge port shall be inside the extent of meshing line, which shall increase the
gas leakage. Normally the suitable length of the horizontal segment is taken to
achieve the satisfactory comprehensive results.

3.9.2 Radial Discharge Port

In order to reduce the discharge flow velocity, the housing shall be hollowed
out along the axial direction as radial discharge port when the axial discharge port is
made, its digging method is same as that of radial suction port. Fig 3-29b shows that
the shape of the radial discharge port is A1-A2-B1-B2. It should be pointed out that
A1-A2 and B1-B2 are the out cycle helix of male and female rotors caused by point A
and B on the discharge end plane.

Similar to the suction port, the discharge port of screw compressors usually
adopts the axial and radial combination to get the maximum flow area, which shall
result in the minimum pressure loss. Moreover, in the circumstance of discharge, the
centrifugal force caused while the gas rotates with rotors is favorable to the radial

99
 discharge port. It is necessary to point out that when the built-in volume ratio of
screw compressors is required to reach a higher value, the discharge angle of male
rotor 1d is always smaller than 01 shown in Fig 3-29. Obviously, radial discharge
port can not be set in this case.

Fig 3-29 Determining the Position and Shape of Radial Discharge Port

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3.9.3 Axial Discharge Start Angles for Typical Profiles

The angle of discharge port of screw compressors mainly depends on the built-
in volume ratio, rotor profile type, torsion angle and rotor tooth ratio. The discharge
angle 1d of male rotor of the common profiles is given in Tab 3-4.

Tab 3-4 Discharge angle of male rotor of common profiles (τ1z=300°)

Built-in Double side Single side SRM- GHH SRM-D Hitachi

volume symmetrical asymmetric A profile profile profile
ratio circular arc cycloid-pintooth
based profile circular arc based profile
profile

2.6 77.6 83.8 84.5 94.10 83.50 92.90

3.6 46.2 52.7 53.4 62.50 52.30 61.30

4.5 30 36.5 37.2 46.10 36.10 44.80

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