Study on the behavior law when milling the material of the Nomex honeycomb core

Atlati

et al. 2021

Environ Sci Pollut Res

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The machining of Nomex honeycomb structures represents a technical and scientific barrier for aeronautical applications. The difficulties encountered during the machining of this type of material are linked to the low density of Nomex paper, and to the low thickness of the walls forming the honeycomb cells of this type of structure. In this work, a finite element calculation code "ABAQUS`-EXPLICIT" was used to optimize and analyze the machining by milling of Nomex honeycomb structures. The main objective of this work is to study the influence of the machining conditions on the cutting forces, and the morphology of the chips.

Section: Resultsmentioning

confidence: 69%

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

Atlati

et al. 2021

Environ Sci Pollut Res

Self Cite

“…On the contrary,The Fy component is not compatible with the experimental results due to removing the damaged elements and the loss of contact with the cutting tool. By comparing the components of the cutting force predicted during milling of the Nomex structure (composite material) and this under the same cutting conditions indicated above, the component Fz is not important but rather the components Fx and Fy [28]. This can be explained by the effect of the geometry of the tool, which has teeth at the level of the cutting edge, and the behavior of the Nomex structure, which is characterized by out-of-plane resistance.…”

Section: Effect Of the Rotation Speed On The Cutting Forcesmentioning

confidence: 89%

Optimization of the milling process for aluminum honeycomb structures

Nouari

Int J Adv Manuf Technol

et al. 2022

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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.

“…It is well known that the rotation and feed rates have a direct influence on the cutting forces, the machined surface quality, and the formation of the generated chips. 3,24,25 In this section, we are interested in studying the influence of the depth of cut on the chip morphology. In this respect, two cutting depths have been examined 2 and 12 mm.…”

Section: Effect Of Cutting Depth On Cut Morphologymentioning

confidence: 99%

Analysis of friction and cutting parameters when milling honeycomb composite structures

Advances in Mechanical Engineering

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.