A force-insensitive impedance compensation method for giant magnetostriction ultrasonic cutting system of Nomex honeycomb composites

Ma, Ke; Wang, Jianjian; Zhang, Chenglong; Feng, Pingfa; Yu, Dingwen; Ahmad, Shahzad

doi:10.1016/j.compstruct.2022.115708

Cited by 16 publications

(3 citation statements)

References 30 publications

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“…stands out with its exceptional electrical insulation, thermal resistance, and mechanical strength properties, rendering it a preferred choice for applications where safeguarding against elevated temperatures and electrical hazards is critical. [3][4][5] Despite its numerous advantages, the process of drilling holes in Nomex® aramid fiber presents challenges due to its distinctive composition and structure. 2,6 When drilling aramid fibers, there are some specific challenges to consider.…”

Section: Introductionmentioning

confidence: 99%

“…12 While specific machinability data concerning Nomex® pressboard remains limited in existing literature, investigations pertaining to drilling applications have been carried out, particularly in the context of honeycomb structures. 2,5,6,19,20 Nomex® honeycomb cores play a pivotal role in sandwich structures and can be perforated utilizing diverse cutting and entry angles. 19 These cores, comprising aramid paper and phenolic resin, have been effectively utilized for the fabrication of sandwich panels.…”

Section: Introductionmentioning

confidence: 99%

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Reducing delamination risk with response surface methodology-supported drilling analysis for Nomex® aramid fiber composites

Yarar

2023

Journal of Composite Materials

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This article presents a comprehensive experimental investigation into the drilling behavior of Nomex®, a type of aramid fiber. The study specifically examines the impact of various cutting parameters and drill bit types on drilling outcomes. While Nomex® offers many advantages, difficult chip evacuation during drilling of aramid fiber composites can lead to surface defects and delamination. The research aims to explore how drilling parameters—such as spindle speed, feed rate—and four distinct drill bit types affect drilling performance. The analysis encompasses factors such as thrust force, torque, and surface roughness, studied under different drilling conditions and with various drill bit types. Moreover, the research assesses peeling and push-out delamination factors to gain insights into drill bit and coating characteristics. An examination of burr and chipping further enhances the comprehension of drilling performance. To determine the most effective drilling conditions, the study employs multi-response optimization. The optimal drilling performance is achieved with a combination of a 0.1 mm/rev feed rate, 1402.82 r/min spindle speed, and HSS-TiN drill type. This configuration successfully integrates responses, resulting in a composite desirability value of 0.95.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Reducing delamination risk with response surface methodology-supported drilling analysis for Nomex® aramid fiber composites

Yarar

2023

Journal of Composite Materials

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“…29 Some work has been carried out on ultrasonic cutting honeycomb composites' cutting force and surface quality. Ma et al 30 designed a new type of ultrasonicassisted machining honeycomb serrated disc tool and optimized the top angle of the tool and found that ultrasonic machining can reduce the number of burrs, cutting force decrease with increasing spindle speed and ultrasonic amplitude and cutting width have the most significant effect on the cutting force. Xiang et al 31 compared the influence of cutting angle on the surface quality and cutting force of honeycomb composites under LTUAM and longitudinal ultrasonic assisted milling (LUAM) by theoretical analysis, and verified it by experiments.…”

Section: Introductionmentioning

confidence: 99%

Investigation on carbon fiber fracture mechanism of honeycomb composites in longitudinal‐torsional ultrasonic‐assisted milling processes

Shi,

Chen,

Yang

et al. 2023

Polymer Composites

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A multi‐edge micro‐tooth longitudinal‐torsional ultrasonic‐assisted milling (LTUAM) model was established based on the hard brittle characteristics of carbon fiber honeycomb composites and the weak strength characteristics of the hole wall interface. The study analyzed the effects of ultrasonic characterization parameters on the cutting force, honeycomb wall width, and surface morphology. The results indicate that using LTUAM significantly reduced the cutting force and decreased the length and height of the burrs at an appropriate ultrasound amplitude. The spindle speed had the least impact on the width of the honeycomb wall, but increased with the longitudinal‐torsional ultrasonic amplitude and feed rate. The maximum error between the simulated and experimental cutting force values was approximately 19%. The longitudinal amplitude and torsional amplitude were 3 and 5 μm, respectively, the length of burrs decreased by 52.7%, and there was less delamination and tearing damage. LTUAM proved to be beneficial in improving cutting performance. Compared with conventional milling (CM), LTUAM resulted in regular fiber fracture morphology and smaller fragments on the honeycomb surface. In addition, the high‐frequency ultrasonic vibration promoted carbon fiber fracture and the surface roughness value under LTUAM was approximately 36.72% smaller than that of CM.Highlights Ultrasonic milling mechanism of carbon honeycomb is studied. Kinematic simulation of the tool of carbon honeycomb was studied during LTUAM. LTUAM promotes the fracture of carbon fibers. A multi‐edge micro‐tooth LTUAM model was established of carbon honeycomb. Deformation of the cell wall can be avoided by ultrasonic vibration of the cutter.

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Influence of cutting tool geometry when milling Nomex honeycomb structure

Zarrouk,

Nouari,

Benbouaza

et al. 2023

Int J Adv Manuf Technol

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A force-insensitive impedance compensation method for giant magnetostriction ultrasonic cutting system of Nomex honeycomb composites

Cited by 16 publications

References 30 publications

Reducing delamination risk with response surface methodology-supported drilling analysis for Nomex® aramid fiber composites

Reducing delamination risk with response surface methodology-supported drilling analysis for Nomex® aramid fiber composites

Investigation on carbon fiber fracture mechanism of honeycomb composites in longitudinal‐torsional ultrasonic‐assisted milling processes

Influence of cutting tool geometry when milling Nomex honeycomb structure

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