In this article, the design parameters of a cutting tool for manufacturing a rotary knife with multi-cutting angles have been studied. An objective function and constraints are defined, and optimized solutions are found by using two methods: global search and sequential quadratic programming. Hobbing and the concept of tooth undercutting were used to manufacture a rotary knife with multi-cutting angles. The proposed method not only improved the manufacturing efficiency over the traditional method (milling and grinding), but also significantly improved the strength of the rotary knife and the chip discharge ability, as shown by the finite-element analysis of the stress distribution and deformation of two different kinds of rotary knives.
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