Simulated and experimental study on the ultrasonic cutting mechanism of aluminum honeycomb by disc cutter

Sun, Jiansong; Kang, Ren Ke; Qin, Yan; Wang, Yidan; Feng, Bairen; Dong, Zhigang

doi:10.1016/j.compstruct.2021.114431

Cited by 20 publications

(6 citation statements)

References 26 publications

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“…For this purpose, RUM technology was applied to overcome the problems of conventional cutting of the honeycomb structure. The interest in this new technology is gradually increasing to machine a wide range of conductive and dielectric materials, including titanium and aluminum alloys [11,12]. For example, Xia et al [13] conducted a study to optimize the dimensions of an ultrasonic disc tool with the aim of evaluating the influence of its geometric properties on its energy density and stiffness.…”

Section: Introductionmentioning

confidence: 99%

Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure

Zarrouk,

Nouari,

Salhi

et al. 2024

Algorithms

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Machining of Nomex honeycomb composite (NHC) structures is of critical importance in manufacturing parts to the specifications required in the aerospace industry. However, the special characteristics of the Nomex honeycomb structure, including its composite nature and complex geometry, require a specific machining approach to avoid cutting defects and ensure optimal surface quality. To overcome this problem, this research suggests the adoption of RUM technology, which involves the application of ultrasonic vibrations following the axis of revolution of the UCK cutting tool. To achieve this objective, a three-dimensional finite element numerical model of Nomex honeycomb structure machining is developed with the Abaqus/Explicit software, 2017 version. Based on this model, this research examines the impact of vibration amplitude on the machinability of this kind of structure, including cutting force components, stress and strain distribution, and surface quality as well as the size of the chips. In conclusion, the results highlight that the use of ultrasonic vibrations results in an important reduction in the components of the cutting force by up to 42%, improves the quality of the surface, and decreases the size of the chips.

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Section: Introductionmentioning

confidence: 99%

Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure

Zarrouk,

Nouari,

Salhi

et al. 2024

Algorithms

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“…Wu Shengyou [11] established a theoretical model of ultrasonic cutting force of disc cutter based on metal cutting theory, indicating that the intermittent cutting action of the disc cutter on the material is the main reason for the reduction of the cutting force, and giving the conditions for realizing the intermittent cutting. Meng Qian [12] based on the kinematics of the disc cutter and cutting force theory analysis, study the application of ultrasonic vibration after a single cycle of the tool and material contact process and force separation process, pointed out that the ultrasonic action can accelerate the initial crack generation before the tool cut into the impact after the cut into the action of the cracks contribute to the expansion of cracks.SUN [13] through the finite element simulation to study the ultrasonic cutting process of the disc cutter cutting aluminum honeycomb material based on the Based on the plastic strain energy theory, a plastic deformation model of honeycomb wall was established, and the alternating up and down cutting of honeycomb wall by the disc cutter caused the honeycomb wall to deform plastically along the upper and lower surfaces of the cutter and then formed the cutting and machined surfaces. Niu Jinglu [14] used ultrasonic cutting honeycomb core experiments with a disc cutter under no-rotation conditions, and used regression analysis to obtain the empirical formula for the cutting force, and pointed out that the surface quality under ultrasonic cutting is better than that without ultrasound, and that increasing the ultrasound amplitude reduces the cutting force.…”

Section: Introductionmentioning

confidence: 99%

Study on cutting force of ultrasonic cutting disc cutter for Nomex honeycomb material

Wu,

Hu,

et al. 2023

Preprint

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To systematically investigate the specific factors influencing cutting force variations in ultrasonic cutting of Nomex honeycomb materials with disc cutters, a comprehensive theoretical framework was developed. This framework incorporates cutting parameters like feed speed, cutting width, and ultrasonic amplitude to establish a theoretical cutting force formula. Through an analysis of ultrasonic vibration-assisted cutting motion trajectories with a disc cutter, a microscopic model of material removal for Nomex honeycomb cutting was developed. This model decouples the isotropic motion of the disc cutter, yielding theoretical cutting force formulas for different directions, elucidating the reduction in cutting force under ultrasonic influence in both the vibration and feed directions. The formulated theoretical cutting force expressions were verified through ultrasonic cutting experiments. Results indicate that when cutting Nomex honeycomb materials with a disc cutter in the vibration direction, cutting force reduction arises from narrowing the effective cutting width between the tool and the material, and from intermittent contact that minimizes tool-material interaction time. A corresponding cutting force expression for this direction was established. In the feed direction, a mechanism similar to intermittent cutting with a straight blade is observed. Ultrasonic vibration's impact stress induces tensile stress in the uncut section, prompting microcrack propagation in the material's front end and reducing fracture stress, thus diminishing the cutting force. A damage factor was introduced to establish the cutting force expression in the feed direction. Error analysis comparing theoretical and experimental cutting force values under varying parameters revealed average errors of 32%, 36%, and 23% for different feed speeds, ultrasonic amplitudes, and cutting widths. These findings provide theoretical backing for optimizing cutting parameters.

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“…The widespread use of NHCs has created an urgent need for their efficient machining processes. Traditional machining methods for NHCs include milling [ 12 ] and thin-blade tool cutting [ 13 , 14 ]. However, these methods suffer from low efficiency, severe machining defects, large cutting forces, rapid tool wear, and severe dust pollution during the process [ 15 , 16 , 17 , 18 ].…”

Section: Introductionmentioning

confidence: 99%

Enabling Thin-Edged Part Machining of Nomex Honeycomb Composites via Optimizing Variable Angle of Disc Cutters

et al. 2023

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Machining Nomex honeycomb composites (NHCs), which are widely-used materials in the aerospace industry, is an imperative process to obtain desired profiles. However, when machining NHCs to obtain a thin-edged surface, some problems can arise due to large cutting forces. To avoid these defects, a method of ultrasonic vibration machining with variable angles of the down milling disc cutter was proposed in this study. The processing principles and motion characteristics of this method were elaborated. A theoretical model of its cutting process was established. The principle of cutting force reduction was qualitatively analyzed based on the model, and an experimental validation was conducted. The results demonstrated that, due to a smaller swing angle in each pass, the proposed method could reduce the fractal dimension of the machined surface by 6.01% compared to 1° with 10° of angle in each pass. And severe machining defects were decreased. Additionally, comparing the process of the fixed 10° angle of ultrasonic vibration machining with the process of a 1° angle in a pass, cutting force can be significantly reduced by 33.5%, demonstrating the effectiveness of the proposed method which improved surface quality by reducing cutting forces.

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Simulated and experimental study on the ultrasonic cutting mechanism of aluminum honeycomb by disc cutter

Cited by 20 publications

References 26 publications

Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure

Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure

Study on cutting force of ultrasonic cutting disc cutter for Nomex honeycomb material

Enabling Thin-Edged Part Machining of Nomex Honeycomb Composites via Optimizing Variable Angle of Disc Cutters

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