Cell wall fracture mechanism in ultrasonic-assisted cutting of honeycomb materials

Abstract

Revealing the ultrasonic cutting mechanism of honeycomb composite is important for determining the acoustic parameters of the ultrasonic system and selecting the parameters of the cutting process. Understanding more details of the stress on the cell wall from ultrasonic vibrating tool and the conditions for cell wall breakage is essential to study the machining mechanism. According to the evolution of contact state between the straight edge cutter and the honeycomb cell wall in a cycle, the cutting force acting on the cell wall is divided into three stages: transverse cutting load action, longitudinal cutting load action, and no cutting load action. The cell wall deflection and stress equations under transverse cutting load were established by applying elastic thin plate small deflection theory. The deformation and fracture characteristics of the honeycomb cell wall were analyzed by combining the analytical and the finite element model. The results showed that the ultrasonic vibration of the cutter greatly improved the stiffening effect of the cell wall and its fracture was caused by the deflection under the transverse cutting load, which exceeded the maximum allowable deformation after local stiffening. In addition, with only longitudinal cutting load, it was difficult to break the critical buckling state that leads to cell wall fracture.

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

“…Jaafar et al 20 used the Hashin failure criterion to simulate the tool milling honeycomb machining process and systematically investigated the influence of cutting parameters on the formation of surface morphology. In addition, for the high-speed milling technology of honeycomb core, the researchers have carried out research on the cutting force model, 21 milling damage characteristics and suppression, 22,23 tool selection and tool wear research, fixation method, 24,25 milling process, [26][27][28] and so on. Previous studies have shown that due to the weak stiffness characteristics of honeycomb composites and the high strength and toughness of fibers, the formation of defects such as burrs, tearing, and crushing cannot be avoided when high-speed milling is used.…”

Investigation of the equivalent circuit and performance of an ultrasonic transducer under a force load

“…It has been widely applied to titanium alloys [1][2][3][4], high-temperature alloys [5][6][7][8], semiconductor wafers [9][10][11][12], engineering ceramics [13][14][15], ceramic matrix * Author to whom any correspondence should be addressed. composites [16,17], and honeycomb composites [18][19][20][21] and other difficult-to-process materials.…”