Optimization of the cutting tool geometry when milling aluminum honeycomb structures

Abstract

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.