Modeling and numerical simulation of the chip formation process when machining Nomex

Int J Adv Manuf Technol

Nouari

Salhi

et al. 2022

Self Cite

The milling of aluminum honeycomb structures represents today an important scientific and technical research topic for many industrial applications: aerospace, aeronautic, automotive, and naval. The difficulties encountered when milling this type of materials are linked to the small thickness of the walls constituting the honeycomb cells and the ductility of the material structure. The milling of cellular composite structures requires specific and rigorous tools. In the present work, a 3D numerical modeling of the milling process of aluminum honeycombs has been developed using Abaqus / Explicit software. The effect of milling parameters, such as the spindle speed, the tilt angle, and the depth of cut have been particularly investigated in terms of cutting forces, surface integritu and chip morphology. To properly analyze and optimize the cutting process, experimental validation was done through milling tests with different cutting conditions. The comparison between numerical simulations and experimental tests shows that the three-dimensional model correctly reproduces the milling of this type of structure.

Section: Effect Of the Rotation Speed On The Cutting Forcesmentioning

confidence: 99%

“…The role of this shredder is to shred the walls and thus free the passage of the tool to advance through the material. As with composite materials (eg Nomex), this accumulation of material has an influence on the cutting forces and on the shape of the chips generated [25]. The figs.…”

Section: Effect Of Cutting Depth On Cutting Forces and Cutter Morphologymentioning

confidence: 99%

Optimization of the milling process for aluminum honeycomb structures

Int J Adv Manuf Technol

Nouari

Salhi

et al. 2022

Self Cite

“…They knew that the size and morphology of the chips depend on the machining conditions. 11,20 The lower the rotation speed and the higher the feed rate, the larger the chip size. As the tool advances, the cut walls rub on the upper surface of the chip until they reach the shredder.…”

Section: Effect Of Cutting Depth On Cut Morphologymentioning

confidence: 99%

“…Several authors have examined the cutting conditions on the surface quality as well as the cutting forces during milling of Nomex honeycomb structures. [11][12][13] For this purpose and compared with the classical experimental methods, the numerical modeling of the machining becomes an economic and technical tool more and more unavoidable. Although it is one of the oldest manufacturing processes, machining is still subject to reliable predictive modeling.…”

Section: Introductionmentioning

confidence: 99%

Analysis of friction and cutting parameters when milling honeycomb composite structures

Advances in Mechanical Engineering

Salhi

Nouari

et al. 2021

Self Cite

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.

“…Milling is the most widely used material removal forming process in the production of mechanical parts (automotive, aerospace) [4]. In this regard, the Numerical studies show that the morphology of the chips and the wear of the cutting tools are closely linked to the machining conditions [5]. Therefore, the production of high quality complex parts depends mainly on the optimization of the cutting conditions.…”

Section: Introductionmentioning

confidence: 99%

Optimization of the cutting tool geometry when milling aluminum honeycomb structures

Salhi²,

Nouari³

et al. 2022

Preprint

Self Cite

The manufacture of aluminum honeycomb structures is a major concern for companies in the aerospace industry, due to its high out-of-plane strength and stiffness-to-weight ratio. However, the shaping of this type of structure represents a technical challenge for engineers and researchers in terms of premature wear of the cutting tool and the quality of the machined surface. The analysis of the parameters influencing the machinability of this type of structure is often based on empirical tests. However, the experimental procedure fails to visualize the mechanism of cut formation due to the high rotational speed of the cutting tool. Consequently, it is then necessary to use reliable numerical models to access instantaneous and much localized physical quantities. To this end, we have developed a 3D finite element model associated with real working conditions using the Abaqus/Explicit analysis software. Based on this model, an experimental validation was carried out by analyzing the appropriate behavior laws. Furthermore, the influence of the geometry of the cutting tool in terms of the number of teeth on the size of the chips, the cutting forces and the quality of the generated surface was analyzed. The results obtained show that the integrity of the cutting tool can be optimized and the quality of the machined surface can be improved.