Wear reduction by toughness enhancement of disc tool in Nomex honeycomb composites machining

Xu, Jifeng; Yue, Qizhong; Zha, Huiting; Yuan, Xinman; Cai, Xiaokang; Xu, Chao; Ma, Yuan; Feng, Pingfa; Feng, Feng

doi:10.1016/j.triboint.2023.108475

Cited by 11 publications

(3 citation statements)

References 34 publications

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“…The highest stress level should be as high as possible within the stress range that the product can physically withstand. In normal cutting of honeycomb materials, the ultrasonic vibration system is mainly subjected to the cutting force in the feed direction, and the maximum range of the normal cutting force load is within 20 N [11]. Due to experimental limitations, the cutting force is considered as a constant force load, and a tension-compression force gauge is used to simulate the primary cutting force acting on the tool during the cutting process.…”

Section: Accelerated Experiments and Data Collectionmentioning

confidence: 99%

“…For the ultrasonic vibration system with amplitude as the degradation metric, the pseudo-failure lifespan follows a Weibull distribution. By substituting the normal cutting force S = 20 N into the Inverse Power-law model in Equation (11), the distribution parameters for the ultrasonic vibration system under normal stress conditions are obtained as: β = 73, η = 27.…”

Section: Univariate Reliability Modelingmentioning

confidence: 99%

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Performance Degradation Modeling and Continuous Worktime Assessment of Ultrasonic Vibration Systems

Wang,

You,

2024

Processes

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In order to assess the stable operating duration of an ultrasonic vibration system, a reliability-based analysis method for the stability of the ultrasonic vibration system is proposed. Firstly, the failure mechanisms of the ultrasonic vibration system are analyzed, and the resonant frequency and amplitude are selected as two degradation features of the system. Subsequently, accelerated degradation experiments under different force loads were conducted, and the degradation model of the ultrasonic vibration system was established by comparing experimental data with degradation, distribution, and acceleration models. Finally, Copula functions were introduced to connect the two degradation features, resonant frequency, and amplitude, and lifetime curves were plotted under the influence of univariate and bivariate degradation factors. Through the analysis of the lifetime curves, the conclusion is drawn that the decay of amplitude is the primary indicator of system lifetime, and it is predicted that the developed ultrasonic vibration system can operate continuously and stably for 26.69 h. This research is of great significance for enhancing the reliability and lifespan management of ultrasonic vibration systems.

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Section: Accelerated Experiments and Data Collectionmentioning

confidence: 99%

Section: Univariate Reliability Modelingmentioning

confidence: 99%

Performance Degradation Modeling and Continuous Worktime Assessment of Ultrasonic Vibration Systems

Wang,

You,

2024

Processes

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“…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 ]. To address these problems, researchers have proposed many improvements to the machining processes for NHCs.…”

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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Performance Degradation Modeling and Continuous Lifetime Assessment of Ultrasonic Vibration Systems

Wang,

Hu,

You

2024

Mechanisms and Machine Science

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Wear reduction by toughness enhancement of disc tool in Nomex honeycomb composites machining

Cited by 11 publications

References 34 publications

Performance Degradation Modeling and Continuous Worktime Assessment of Ultrasonic Vibration Systems

Performance Degradation Modeling and Continuous Worktime Assessment of Ultrasonic Vibration Systems

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

Performance Degradation Modeling and Continuous Lifetime Assessment of Ultrasonic Vibration Systems

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