Investigation on damage reduction method by varying cutting angles in the cutting process of rectangular Nomex honeycomb core

Xu, Qihao; Bao, Yan; Wang, Yiqi; Gao, Hang

doi:10.1016/j.jmapro.2021.07.006

Cited by 28 publications

(4 citation statements)

References 31 publications

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“…However, this accumulation is reduced when spindle speeds are high, tending to reduce the cutting forces. [28] ANOVA shows that DoC is the most important factor in the case of CE. It is because the DoC allows uniform material 10 indicate this correlation, as DoC is the prime significant factor in the calculation of CE.…”

Section: Discussionmentioning

confidence: 97%

Enhancing Cutting Efficiency and Minimizing Forces for Nomex Honeycomb Core Using Grey Relational Analysis and Desirability Function Analysis

Habib,

Khan,

Munir

et al. 2023

Small Methods

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Nomex Honeycomb core is the foundational building block for manufacturing aerospace composite components. Its usage requires machining honeycomb in complex aerodynamic profiles where the quality of the core is governed by accuracy and precision of cut profiles. The assessment of accuracy and precision is directly related to forces induced in the cutting tool and cutting efficiency. These two parameters form the basis of a multi‐objective function that this paper aims to optimize for the milling operation. The parameter of depth of cut considered in this paper has not been analyzed in a multi‐objective optimization study of the Nomex Honeycomb core previously. A Taguchi‐based array of Design of Experiments followed by Analysis of Variance and correlation analysis is utilised. The results indicate that the most significant factor is the feed rate, with a percentage contribution of 72% for the cutting forces and depth of cut, with a percentage contribution of 85% in the case of cutting efficiency. The two parameters are optimized using Desirability Function Analysis and Grey Relational Analysis. The results are validated through experimental runs with an error within 5% of the statistical predictions, with the percentage improvement in cutting forces for optimum runs as compared to the worst experimental run at 47.8%. The percentage improvement in cutting efficiency likewise is 11%.

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Section: Discussionmentioning

confidence: 97%

Enhancing Cutting Efficiency and Minimizing Forces for Nomex Honeycomb Core Using Grey Relational Analysis and Desirability Function Analysis

Habib,

Khan,

Munir

et al. 2023

Small Methods

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“…During the granite sawing, the diamonds are cut in from the workpiece surface, cut out from the bottom end, and the cutting angle ε [33] is from the maximum to the minimum. Because the diamond circular saw blade tools have slots, the cutting angle ε 1max of the diamonds of the front segment (Red particles in Fig.…”

Section: The Proposed Force Model 221 Number Of Segments In the Sawin...mentioning

confidence: 99%

Modeling for prediction of sawing force based on the maximum undeformed chip distribution in the granite sawing

Kang

Zhang

Duan

et al. 2022

Int J Adv Manuf Technol

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Sawing by circular saw blades is predominant in the mechanized treatment of natural stone. The predictive sawing force is crucial for optimizing, controlling, and monitoring the sawing process. In this work, a novel model for predicting sawing force, which is based on the distribution of the undeformed chip thickness at the sawing contact arc, was proposed. Based on the analysis of the chip geometry of the circular saw blade, the segment surface was divided into the front end and rear end according to the contact pattern between the segment and granite, and the models of the maximum undeformed chip thickness of diamond particles on the front end and rear end were established. Results suggest that the new proposed force model fully considered the distribution of undeformed chips compared with the current model. And the novel model has higher prediction accuracy, the mean maximum absolute error rate was within 3.77%, and the maximum absolute error rate was within 7.83%. Through theoretical analysis, the ratio (is 1.67) of the maximum thickness of the undeformed chips of the front segment and rear segment can fully explain the wear nonuniformity of the segment. The proposed model is of great signi cance to the optimization of saw blade structure and process parameters.

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“…Qiu et al 16 established a cutting force calculation model for honeycomb composites considering the weak rigidity characteristics of honeycomb structure and achieved accurate prediction of cutting forces at different cutting angles, and combined with a large number of experimental data found that the cutting force increased significantly when the cutting angle was more significant than 75°. Xu et al 17 investigated the effects of the cutting angle, entry angle, and meshing angle on the honeycomb surface morphology, and proposed a new method to control the range of cutting angles to reduce damage. Qin et al 18 classified the burr damage characteristics generated during honeycomb processing and classified them into three categories: block burr, line burr, and point burr, which an image extraction method based on regression analysis and dimensionality reduction algorithm was proposed to realize the extraction of burr damage data.…”

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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Investigation on damage reduction method by varying cutting angles in the cutting process of rectangular Nomex honeycomb core

Cited by 28 publications

References 31 publications

Enhancing Cutting Efficiency and Minimizing Forces for Nomex Honeycomb Core Using Grey Relational Analysis and Desirability Function Analysis

Enhancing Cutting Efficiency and Minimizing Forces for Nomex Honeycomb Core Using Grey Relational Analysis and Desirability Function Analysis

Modeling for prediction of sawing force based on the maximum undeformed chip distribution in the granite sawing

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

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