Stability analysis and experimental research on ultrasonic cutting of wave-absorbing honeycomb material with disc cutter

Abstract

To address the problem of the poor stability of ultrasonic machining of wave-absorbing honeycomb materials, this paper takes ultrasonic cutting of wave-absorbing honeycomb materials with a disc cutter as the research object and establishes a multi-degree-of-freedom mathematical model of the cutting system based on the relative positions of the tool and the honeycomb material and the motion characteristics of the tool. On this basis, modal analysis of the disc tool and the honeycomb cellular element wall plate is carried out to draw the Lobe diagram of ultrasonic cutting stability, the process experimental parameters are determined according to the solved stability Lobe diagram, and machining stability verification experiments are carried out. The experimental results show that the machining parameters in the stable region of the Lobe diagram result in a neat and clean surface, less fibre pullout, a complete outer substrate, and less tool wear than those in the critical and unstable regions, thus verifying the correctness of the theoretical model and the stability Lobe diagram.

Research on key technology of ultrasonic CNC machining programming of honeycomb core parts based on feature recognition

“…However, milling processing of honeycomb core composites, as a key step from the development to the application of honeycomb materials, affects the final performance of honeycomb materials. Due to the orthotropic anisotropy and non-homogeneous structure of honeycomb materials, there are problems such as high cutting forces, high cutting temperatures, serious fiber pull-out, and low machining efficiency in traditional milling processing [2]. Ultrasonic CNC machining, as an emerging technology, can reduce tool wear and effectively overcome the shortcomings of traditional milling [3].…”

Study on Characteristics of Tool Wear and Breakage of Ultrasonic Cutting Nomex Honeycomb Core with the Disc Cutter

“…So, it is critical to research disc cutter tool wear and breakage. On the research methods of tool wear and breakage in processing honeycomb material, Guo et al [16] used an optical microscope to study the chipping law during ultrasonic cutting of wave-absorbing honeycomb material with the disc cutter and showed that the number of chipping edges and notches increased with the increase in cutting length. David et al [17] conducted tool wear analysis of the entire high-speed milling of the Nomex honeycomb core using a high-speed camera and clearly observed that the tool underwent a morphological change process such as significant wear of the lowest teeth on the tool and missing multiple cutting edges.…”