In this work we present an innovative method of rotor milling for flexible multifunctional machines. As an alternative to the disc cutters which are often employed in traditional milling machines, we propose a new tool, a finger cutter, which integrates easily with flexible multi-functional machines. This allows much smoother operation with lower required torque which is in line with the characteristics of flexible machines. This paper describes basic geometrical condition to generate the finger cutter profile from the rotor profile, the mathematical formulation, the basic tool design and grinding procedure of the cutter blades. It also discusses the machining process, productivity and accuracy of the proposed method. We believe that this method opens a new way of manufacturing large rotors with fewer production steps while maintaining required tolerances.
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