Mechanism

and
Mechanism and Machine Theory 41 (2006) 405–414
Machine Theory
www.elsevier.com/locate/mechmt

Simple explicit formulae for calculating limit dimensions

to avoid undercutting in the rotor
of a Cycloid rotor pump
Zhonghe Ye *, Wei Zhang, Qinghai Huang, Chuanming Chen
College of Mechanical Engineering, Fuzhou University, Fuzhou,
Fujian 350002, PR China

Received 10 March 2004; received in revised form 10 June 2005; accepted 4 July 2005
Available online 6 September 2005

Abstract

A new and simple method is used to derive the formulae for the tooth profile of the small rotor in a Cycloid
rotor pump. Undercutting is avoided by calculating the maximum radius of curvature of the small rotor tooth
profile on the convex section. It is found that undercutting can be avoided so long as the maximum value is not
larger than zero. The derivation of the formula for the radius of curvature is based not on the tooth profile
formulae of the small rotor, but on those of the locus of the centre of the circular tooth of the large rotor rel-
ative to a coordinate system fixed to the small rotor. This simplified method yields explicit formulae for cal-
culating limit dimensions of the large rotor to avoid undercutting on the tooth profile of the small rotor.
Ó 2005 Elsevier Ltd. All rights reserved.

Keywords: Cycloid rotor pump; Radius of curvature; Undercutting; Limit dimensions

1. Introduction

Shown in Fig. 1 is a Cycloid rotor pump. The tooth numbers of the small rotor 1 and the large
rotor 2 are Z1 and Z2(=Z1 + 1), respectively. The small rotor 1 drives the large rotor 2 which

*
Corresponding author.
E-mail address: zhonghe.ye@fzu.edu.cn (Z. Ye).

0094-114X/$ - see front matter Ó 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mechmachtheory.2005.07.001
406 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414

y2 y1

r2
d
O2 P F2 x1
e O1 H1 x2
S1 r0
r1
T1

Fig. 1. A Cycloid rotor pump with e = 1, d = 6 and r0 = 2.

rotates in the pump body. The two rotors rotate in the same direction about O1 and O2 and the
radii of their pitch circles are r1 and r2, respectively. The two pitch circles are tangent at the pitch
point P and the distance between the centres of the two rotors is e. Therefore, r1 = Z1e, r2 = Z2e.
The tooth profile of the large rotor 2 is a circular arc centred at point F2 and its radius is r0. The
distance between the centre F2 and the centre of rotation O2 is d. There is a transition curve con-
necting the circular tooth and the dedendum of the large rotor. The tooth profile of the small rotor
is an envelope of the circular tooth of the large rotor.
The principal of operation is as follows. Since all teeth of the small rotor are permanently in
mesh with the teeth of the large rotor, many independent closed working spaces exist between
the two rotors. While the two rotors rotate simultaneously in the same direction, the volume of
each closed working space changes periodically. As the volume of the closed working space be-
comes larger, a lowering of the pressure will occur inside the closed working space and the oil
from the oil reservoir will be sucked through the inlet port. Similarly, when the volume of the
closed working space becomes smaller, the oil inside is extruded through the outlet port. In this
way, oil is pumped continuously through the inlet and outlet ports.
When designing the Cycloid rotor pump, r0 and d are two important dimensions. If r0 is larger
than a maximum value or d is less than a minimum value, then the enveloped tooth profile of the
small rotor will self-intersect. (See curve A1B1C1D1E1 in the enlarged figure on the right side of
Fig. 4.) The tooth profile of the small rotor will therefore be undercut. This will allow a large
backlash between tooth profiles of the two rotors and oil leakage thus becomes a potential prob-
lem. It is consequently important to calculate limit dimensions to avoid undercutting on the small
rotor during the design stage.
Using a partial derivative method, Mimmi and Pennacchi [1] derived the formulae for the tooth
profile of the small rotor. Then, using the method for determining and tracing the limit curve, they
obtained transcendental equations for the calculation of the limit dimensions to avoid undercut-
 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414 407

ting (see [1], Eqs. (31) and (32) on p. 486). The derivation is long and complicated with the added
disadvantage that the transcendental equations must be solved numerically.
In contrast, this paper presents a simple method to derive the formulae of the tooth profile of
the small rotor. An innovative method is used to derive a simple formula for calculating the radius
of curvature of the tooth profile of the small rotor. A formula for calculating the maximum radius
of curvature of the tooth profile of the small rotor is then obtained. Lastly, by setting the maxi-
mum radius of curvature to zero, simple explicit formulae are found for calculating the limit
dimensions of the larger rotor. With these simple explicit formulae, the calculation of the limit
dimension becomes a much simpler task.

2. Formulae for the tooth profile of the small rotor

The method of derivation is as follows. It may be seen that when the small rotor 1 rotates coun-
ter-clockwise through an angle /1 about O1 relative to an axis passing through O1O2, the large
rotor 2 will rotate counter-clockwise about O2 through an angle /2 where /2 = (Z1/Z2)/1. Rotor
1, rotor 2 and the frame are then assumed to be fixed together and the whole mechanism is rotated
clockwise about O1 through an angle /1. The small rotor 1 thus returns to its original position, as
shown in Fig. 2. This is equivalent to imagining that the frame O1O2 rotates clockwise around O1
relative to the small rotor 1 through angle /1 while the large rotor 2 rotates counter-clockwise
around O2 relative to the frame by an amount /2. In Fig. 2, the profiles of the two rotors mesh
at point K and the two pitch circles are mutually tangential at the pitch point P. According to the
basic laws of gearing, a common normal passing through the meshing point K of the two profiles
must pass through the pitch point P of the two pitch circles. Because the tooth profile of the large
rotor is a circular arc, all normals to the circular arc must pass through the centre F2. Therefore,
the three points F2, K and P lie on the same straight line. During meshing, the locus of the mesh-
ing point K relative to the small rotor 1 is the tooth profile of the small rotor 1.

r2 M
y1
y2

L
O2 e O φ1 φ 2
1 d N x1
φ1 φ 2 H1
θ F2 x2

r1 S1 K r0
P
G
T1 Q

Fig. 2. Coordinates of mesh point K.

408 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414

In the co-ordinate system x2
y2 which is fixed to the large rotor 2, the formulae of the tooth
profile of the large rotor 2, or co-ordinates (x2K ; y 2K ) of the meshing point K may be expressed as
parametric formulae with h as a parameter
(
x2K ¼ d
r0 cos h
ð1Þ
y 2K ¼
r0 sin h
We now make a simple geometrical construction drawing a line from O2 perpendicular to F2K
intersecting with the extension of line F2K at point G. Thus, in right triangle O2GF2, we have
O2 G ¼ O2 F2 sinð\O2 F2 GÞ ¼ d sin h ð2Þ
\O2PG is an outer angle of triangle O2PF2, therefore, \O2PG = \PO2F2 + \O2F2P = /2 + h.
In right triangle O2PG,
O2 G ¼ O2 P sinð/2 þ hÞ ¼ ðe þ r1 Þ sinð/2 þ hÞ ð3Þ
Solving Eqs. (2) and (3) simultaneously, we have
d sin h ¼ ðe þ r1 Þ sinð/2 þ hÞ
Therefore



1 d sin h
/2 ¼ sin
h ð4Þ
e þ r1
Using the well-known co-ordinate transform formula, the co-ordinates ðx2K ; y 2K Þ of point K in
co-ordinate system x2
y2 can be transformed into the co-ordinates (xK,yK) of the same point
in the co-ordinate system x1
y1 that is fixed to the small rotor 1. Hence
2 3 2 32 2 3
xK cosð/1
/2 Þ sinð/1
/2 Þ
e cos /1 xK
6 7 6 76 2 7
4 y K 5 ¼ 4
sinð/1
/2 Þ cosð/1
/2 Þ e sin /1 54 y K 5
1 0 0 1 1
from which we obtain
(
xK ¼ x2K cosð/1
/2 Þ þ y 2K sinð/1
/2 Þ
e cos /1
ð5Þ
y K ¼
x2K sinð/1
/2 Þ þ y 2K cosð/1
/2 Þ þ e sin /1
We now have Eqs. (1), (4) and (5) for calculating the coordinates of the tooth profile of the small
rotor 1 with h as parameter. Firstly, x2K and y 2K are calculated from Eq. (1), then /2 is calculated
from Eq. (4). Lastly, putting x2K , y 2K and /2 into Eq. (5), we obtain the coordinates of the tooth
profile of the small rotor 1.
The tooth profile of the small rotor is an envelope of the circular tooth of the large rotor 2.
Usually, equations of envelope should be derived by partial derivative method as that used by
Mimmi and Pennacchi [1]. However, no derivation is used in this paper to derive Eqs. (1), (4)
and (5) for calculating the coordinates of the tooth profile of the small rotor 1. We can see from
the above derivation process that, although Eqs. (1), (4) and (5) derived in this paper are the same
as Eqs. (8), (14) and (15) of Mimmi and Pinnacchi [1], the derivation process presented here is
much simpler.
 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414 409

From Eq. (4), we can see that deþr sin h

1
: the argument of the sin
1 function: must not be greater
than 1. Therefore, the maximum value hmax of h is hmax ¼ sin
1 ðeþr d
1
Þ.
d sin h
From Eq. (4) we can see that sinð/2 þ hÞ ¼ eþr1 . Care must be taken when calculating /2 from
Eq. (4) as there will be two different values of /2 corresponding to any value of h. For the first
half-section of the tooth profile of the small rotor from point H1, h should increase from 0 to hmax,
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
sin h 2
and cosð/2 þ hÞ ¼ þ 1
ðdeþr 1
Þ . For the remaining half-section of the tooth profile to point T1,
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
sin h 2
h should decrease from hmax to 0 and cosð/2 þ hÞ ¼
1
ðdeþr 1
Þ . The correct values of
(/2 + h) must then be determined by the sign and values of both sinð/2 þ hÞ and cosð/2 þ hÞ.
When the mesh point moves from the first point H1 to the last point T1 along the tooth profile
of the small rotor 1, /2 will increase from 0 to p and \H1 O1 T1 ¼ Zp1 .

3. Formula for calculating the radius of curvature for the tooth profile of the small rotor

As is well known, during the design of the cam profile of a plate cam mechanism with roller
follower, if the roller radius is too large, then the cam contour developed according to the pitch
curve will be self-intersecting (see [2], Fig. 5–26c on p. 91). To avoid this phenomenon, all values
of the radius of curvature of the cam profile must be calculated and checked. The cam contour on
the convex section will not be self-intersecting so long as the minimum radius of curvature is larger
than zero, or the minimum radius of curvature of the pitch curve is larger than the roller radius.
Self-intersecting of the cam contour can therefore be avoided by controlling the radius of curva-
ture of the cam contour. As distinct from the method in [1], self-intersecting of the small rotor is
avoided in this paper by calculating and controlling the radius of curvature of the tooth profile of
the small rotor. Simple explicit formulae are derived which enable the limit dimensions to be cal-
culated directly and easily.
In Fig. 2, the co-ordinates (xO2 , y O2 ) of rotating centre O2 of the large rotor 2 in the co-ordinate
system (x1
y1) fixed to the small rotor 1 are
(
xO2 ¼
e cos /1
y O2 ¼ e sin /1

The co-ordinates (xF 2 , y F 2 ) of the locus MNF2Q of centre F2 of the circular tooth of the large
rotor 2 in co-ordinate system (x1
y1) are
(
xF2 ¼ xO2 þ O2 L ¼
e cos /1 þ d cosð/1
/2 Þ
ð0 6 /2 6 pÞ ð6Þ
y F2 ¼ y O2
F2 L ¼ e sin /1
d sinð/1
/2 Þ

As is well known, the formula for the radius of curvature of a parametric curve is [2]
ððx0 Þ2 þ ðy 0 Þ2 Þ3=2
q¼ ð7Þ
x0 y 00
x00 y 0
where x and y are the coordinates of the parametric curve, x 0 and y 0 are the first derivatives of x
and y with respect to the parameter and x00 and y00 are the second derivatives of x and y with re-
spect to the parameter, respectively.
410 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414

Differentiating xF 2 and y F 2 in Eq. (6) with respect to /2 results in x0F2 , y 0F2 , x00F2 , and y 00F2 . Substi-
tuting them into Eq. (7) yields a simpler formula with /2 as parameter for the calculation of the
radius of curvature qF 2 of the locus MNF2Q of the point F2 relative to the small rotor 1 as follows:
ððZ 2 eÞ2 þ d 2
2eZ 2 d cos /2 Þ3=2
qF2 ¼ ð0 6 /2 6 pÞ

Z 32 e2
d 2 þ eZ 2 ðZ 2 þ 1Þd cos /2
Since the tooth profile of the small rotor is an envelope of the circular tooth of the large rotor 2,
the normal distance from the centre F2 of the circular tooth of the large rotor to the tooth profile
of the small rotor is always equal to the radius r0 of the circular tooth. The locus MNF2Q of the
centre F2 and the tooth profile of the small rotor 1 are thus two parallel curves. The difference
between the radii of curvature of two corresponding points on these two parallel curves is the ra-
dius r0 of the circular tooth. Therefore, the radius of curvature qK of the tooth profile of the small
rotor is qK = qF 2 + r0, or,
ððZ 2 eÞ2 þ d 2
2eZ 2 d cos /2 Þ3=2
qK ¼ þ r0 ð0 6 /2 6 pÞ ð8Þ

Z 32 e2
d 2 þ eZ 2 ðZ 2 þ 1Þd cos /2

4. Explicit formulae for calculating the limit dimensions to avoid undercutting

In Fig. 1 (and Fig. 3 of [1]), the Cycloid rotor pump has the following dimensions: e = 1,
Z1 = 4, Z2 = 5, d = 6 and r0 = 2. Shown in Fig. 3 is the relationship between radius of curvature
qK of the tooth profile of the small rotor and angular displacement /2 of the large rotor 2. From
Figs. 1 and 2, we can see that, when /2 = 0, the two tooth profiles mesh at the point H1. When /2
increases from 0, the mesh point moves downwards from the point H1 along the tooth profile. The
radius of curvature of the tooth profile in section H1S1 is positive (profile H1S1 is concave). At
inflexion point S1, the radius of curvature changes suddenly from positive infinite to negative infi-
nite. The radius of curvature of the tooth profile in section S1T1 is negative (profile S1T1 is con-
vex), as shown in Fig. 3. The radius of curvature at point /2 is the maximum value of all radii of

ρ
K

S1 φ*2 π
0
H1 T1 φ 2
kmax

Fig. 3. Relationship curve between qK and /2 corresponding to Fig. 1.

 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414 411

curvature in section S1T1, denoted as qK max. The value of qK max at /2 is less than zero. The tooth
profile of the small rotor is smooth, without any cusp.
From Eq. (8), we have qK = 1 when the denominator is zero. Therefore, the inflexion point S1
occurs at the following position:

3 2 
Z2e þ d 2
/2 ¼ cos
1
eZ 2 ðZ 2 þ 1Þd
If the radius r0 of the circular tooth of the large rotor increases, then qK max will increase. If r0 is
larger than a limit value, then qK max will be positive and the tooth profile of the small rotor will be
self-intersecting. For example, in the Cycloid rotor pump shown in Fig. 4, e = 1, Z1 = 4, Z2 = 5,
d = 6 and r0 = 3. The tooth profile of the small rotor is undercut, as curve A1B1C1D1E1 shown in
the enlarged figure on the right side of Fig. 4. Shown in Fig. 5 is the relationship between qK and
/2 for this Cycloid rotor pump. At inflexion point S1, the radius of curvature changes suddenly
from positive infinite into negative infinite. After the inflexion point S1, the radius of curvature
at point /2 has the maximum value qK max. Since qK max is larger than zero, there are two points

y2 y1 A1

D1
O2 O1 P F2 x 1 B1
e H1 x2 r0
C1
r0 E1

Fig. 4. A Cycloid rotor pump with e = 1, d = 6 and r0 = 3.

ρk

ρ kmax
H1
S1 D1 E1 π
C1 φ *2 T1 φ
2

Fig. 5. Relationship curve between qK and /2 corresponding to Fig. 4.

412 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414

with zero radius of curvature. They correspond to the two cusps C1 and D1 on the curve
A1B1C1D1E1. The actual profile after cutting is H1A1B1E1. This will produce backlash between
the two rotors during running with consequent oil leakage. To avoid this self-intersecting, the
point with zero radius of curvature must be avoided, i.e. the maximum value qK max should not
be larger than zero.
In order to calculate qK max, Eq. (8) is differentiated with respect to /2 and we set dqK
d/2
¼ 0. Hence
1=2
dqK 3eZ 2 d sin /2 ðe2 Z 22 þ d 2
2eZ 2 d cos /2 Þ
¼
d/2
e2 Z 32
d 2 þ eZ 2 ðZ 2 þ 1Þd cos /2
eZ 2 ðZ 2 þ 1Þd sin /2 ðe2 Z 22 þ d 2
2eZ 2 d cos /2 Þ3=2

¼0
ð
e2 Z 32
d 2 þ eZ 2 ðZ 2 þ 1Þd cos /2 Þ2

from which we obtain

2e2 Z 32
e2 Z 22
Z 2 d 2 þ 2d 2
cosð/2 Þ ¼ ð9Þ
eZ 2 ðZ 2 þ 1Þd

Substituting Eq. (9) into Eq. (8), yields an explicit formula for calculating qK max, the maximum
radius of curvature of the tooth profile for the small rotor in section S1T1 as follows:
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
27ðZ 2
1Þðd 2
e2 Z 22 Þ
qKmax ¼
þ r0 ð10Þ
ðZ 2 þ 1Þ3=2
Setting qK max = 0 results in an explicit formula for calculating the maximum value r0 max of the
radius r0 of the circular tooth of the large rotor to avoid undercutting on the small rotor 1
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
27ðZ 2
1Þðd 2
e2 Z 22 Þ
r0 max ¼ ð11Þ
ðZ 2 þ 1Þ3=2
If r0 has been determined beforehand, then the minimum distance dmin between the centre F2 of
the circular tooth of the large rotor and the rotating centre O2 of the large rotor 2 can be calcu-
lated by the following explicit formula derived from Eq. (11):
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
3
r20 ðZ 2 þ 1Þ
d min ¼ þ e2 Z 22 ð12Þ
27ðZ 2
1Þ
Using Eqs. (11) and (12) it is very easy to calculate limit dimensions. If e = 1, Z1 = 4, Z2 = 5 and
d = 6, then r0 max = 2.34521. The Cycloid rotor pump in Fig. 6 of [1] has these limit dimensions.
Solving the two Eqs. (31) and (32) on p. 486 of [1] simultaneously and numerically will get the
same results. The maximum radius qK max of curvature of the tooth profile of this small rotor
on the convex section is equal exactly to zero. If e = 1, Z1 = 5, Z2 = 6 and d = 7, then
r0 max = 2.26199. If e = 1, Z1 = 3, Z2 = 4 and d = 5, then r0 max = 2.41495. Obviously, Eqs. (11)
and (12) are much easier to use than Eqs. (31) and (32) of Mimmi and Pennacchi [1] which must
be solved numerically.
 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414 413

5. Discussion

Eqs. (1), (4), and (5) are those for calculating the coordinates of the tooth profile of the small
rotor. Eq. (5) contain x2K and y 2K which are functions of h. Therefore, Eqs. (5) are also functions of
h. From Eq. (4) we can see that /2 is also a function of h and contains an inverse sine function. If
xK and yK in Eqs. (5) are differentiated twice with respect to h and the result is substituted into Eq.
(7), then the resulting formula for the radius of curvature of the tooth profile of the small rotor
will be very complicated. It will be impossible to obtain an explicit formula similar to Eq. (9) for
calculating /2 corresponding to the maximum radius of curvature qK max and /2 has to be solved
numerically. Consequently, it is impossible to derive an explicit formula similar to Eqs. (11) and
(12) for calculating limit dimensions for the avoidance of undercutting on the small rotor.
The pitch curve and the cam contour are parallel curves and the normal distance between them
is the radius of the roller. Therefore, the difference between the radii of the curvature of two cor-
responding points on these two curves is also equal to the radius of the roller. In almost all text-
books, the radius of curvature of the cam contour of a plate cam mechanism with roller follower is
not derived by direct double differentiation of the cam contour formulae. Instead, the radius of
curvature of the pitch curve is derived first by twice differentiating the pitch curve formulae.
The required radius of the curvature of the cam contour is then the radius of curvature of the
pitch curve minus the roller radius.
It is not generally appreciated why the radius of curvature of the cam contour is not derived
directly by double differentiation of the formulae of the cam contour. The reason is that the
cam contour formulae contain coordinates of the pitch curve and differential terms (Refer to
Eqs. (5–14), p. 87 in book [2]). Therefore, these formulae will be much more complicated than
those of the pitch curve. If the formulae for the radius of curvature of the cam contour are derived
directly by differentiating the cam contour formulae, then the derivation process will be very te-
dious and the resulting formulae will be very complicated. However, the formula of the radius of
curvature of the pitch curve derived based on the formulae of the pitch curve is much simpler. (See
Eqs. (5–19) on p. 90 of book [2].)
To summarize then, the new approach is as follows: Eqs. (5) for the tooth profile of the small
rotor are not used to derive the formula for the radius of curvature of the tooth profile of the small
rotor. Instead, Eq. (6) for the locus MNF2Q of the centre F2 are used first to derive the formula of
the radius qF2 of curvature of the locus. Then, the simpler Eq. (8) for the radius of curvature qK of
the tooth profile of the small rotor is obtained by adding qF2 and the radius r0 of the circular tooth.
The variable /2, not h, is used as parameter in Eq. (6). These equations have no difficult func-
tions such as sin
1 . They are much simpler to deal with than Eqs. (5). Consequently, the deriva-
tion of Eq. (8) for the radius of curvature based on Eq. (6) is much simpler. Only based on this
simple Eq. (8) can the explicit Eqs. (11) and (12) be derived for calculating the limit dimensions to
avoid undercutting on the small rotor.

6. Conclusion

It is important to calculate limit dimensions to avoid undercutting on the small rotor. Different
from the methods used by Mimmi and Pennacchi [1] who derived transcendental equations for the
414 Z. Ye et al. / Mechanism and Machine Theory 41 (2006) 405–414

calculation of the limit dimensions, some simple explicit formulae are found in this paper for cal-
culating the limit dimensions. First, the formulae of the tooth profile of the small rotor are derived
without any derivation. Equation for the locus of the centre F2 are used to derive the formula of
the radius qF2 of curvature of the locus. Then, the simpler formula for the radius of curvature qK
of the tooth profile of the small rotor is obtained by adding qF2 and the radius of the circular
tooth. Formula of the maximum radius qK max of curvature is derived by setting dq K
d/2
¼ 0. Lastly,
by setting qK max to zero, simple explicit formulae are found for calculating the limit dimensions of
the larger rotor.

Acknowledgements

The authors thank Dr. M. R. Smith, of University of Newcastle upon Tyne, for his patient
instructions and checking.

References

[1] G.C. Mimmi, P.E. Pennacchi, Non-undercutting conditions in internal gears, Mechanism and Machine Theory 35
(2000) 477–490.
[2] Ye Zhonghe, Lan Zhaohui, M.R. Smith, Mechanisms and Machine Theory, Higher Education Press, Beijing, 2001,
ISBN 7-04-009234-4, July (in English).