The machining of Nomex honeycomb structures represents a technical and scientific barrier for aeronautical applications. The difficulties encountered during the machining of this type of material are linked to the low density of Nomex paper, and to the low thickness of the walls forming the honeycomb cells of this type of structure. In this work, a finite element calculation code "ABAQUS`-EXPLICIT" was used to optimize and analyze the machining by milling of Nomex honeycomb structures. The main objective of this work is to study the influence of the machining conditions on the cutting forces, and the morphology of the chips.

In machining, tool/workpiece interface parameters are complicated to estimate by experimental means alone. Numerical methods can then give critical solutions to predict and analyze the parameters influencing the machining. The friction between the tool and the cutter has a direct influence on the milling parameters. Therefore, it is necessary to understand the friction mechanism between the tool and the workpiece to estimate the milling parameters of Nomex honeycomb structures correctly. This work aims to present a 3D Finite Element numerical model allowing the prediction of the cutting forces correctly, the morphology of the chips, and the surface quality generated during the milling of this type of structure. These studies were obtained using the commercial software ABAQUS/Explicit. It has been demonstrated that the coupling between the isotropic elastoplastic approach and the Coulomb friction law can easily simulate the milling of Nomex honeycomb structures and gives excellent results in comparison with those obtained experimentally.

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