Twin-screw compressors are widely used in industry for their reliability and efficiency. This study examines variable lead rotor designs to improve volumetric and isentropic performance. A thermodynamic model in Mathematica was developed to analyze leakage, pressure variation, and power consumption. Lead curves were optimized using uniform design, RBF prediction, and global optimization. Results demonstrate enhanced performance and an effective approach for rotor design optimization.

This method presents collaborative optimization of rotor profiles and lead curves for twin-screw compressors. By modifying the sealing line and integrating rotor geometry with global optimization in Mathematica, an optimal profile is obtained. Mathematical and force models evaluate discharge volume, volumetric, and isentropic efficiency. The lead curve is parameterized, and an RBF model with optimization determines optimal parameters, improving design efficiency and performance.

This study provides the air compressor industry with an optimized design methodology integrating high efficiency, low vibration, and manufacturability. It supports energy-efficient compressor development, reduces energy consumption and leakage, and improves performance and reliability. The approach can be directly applied to product design, shortening development time and lowering costs, thereby enhancing product value and international competitiveness.