Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting

2021 ◽  
Author(s):  
Yidan Wang ◽  
Renke Kang ◽  
Yan Qin ◽  
Qian Meng ◽  
Zhigang Dong
Keyword(s):  
Disc Cutter ◽  
Honeycomb Core ◽  
Machining Quality ◽  
Inclination Angles ◽  
Nomex Honeycomb ◽  
Ultrasonic Cutting

A novel method of blade-inclined ultrasonic cutting Nomex honeycomb core with straight blade

2020 ◽  
pp. 1-34
Author(s):  
Yidan Wang ◽  
Renke Kang ◽  
Zhigang Dong ◽  
Xuanping Wang ◽  
Dehong Huo ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Honeycomb Core ◽  
Straight Blade ◽  
Machining Quality ◽  
Cutting Geometry ◽  
Novel Method ◽  
Nomex Honeycomb ◽  
Honeycomb Cores ◽  
Ultrasonic Cutting

Abstract Ultrasonic cutting with a straight blade is an advanced cutting method for Nomex honeycomb core. However, crushing has generally been observed on the machining surface of the honeycomb core in ultrasonic cutting (UC). In this paper, aiming at avoiding crushing, a new blade-inclined ultrasonic cutting (BIUC) method is proposed to decrease the geometric interference between the cutting tool and the honeycomb cores. The cutting geometry systems of UC and BIUC with a straight blade are systematically established to study the effect of cutting geometry on the machining quality. The crushing degrees caused by the major flank under different tool orientations in UC and BIUC are analyzed. The causes of crushing during the machining of the honeycomb core were revealed from aspects of machining quality, cutting force and geometric interference between the major flank and the material. Experiments on quantitive analysis of crushing and cutting forces verify that the BIUC method is able to avoid crushing by controlling the cutting angle. This paper provides a new method for solving the crushing problem in machining honeycomb core with the straight blade.

scholarly journals Cutting Force Prediction and Experiment Verification of Paper Honeycomb Materials by Ultrasonic Vibration-Assisted Machining

2020 ◽  
Vol 10 (13) ◽  
pp. 4676 ◽  
Author(s):  
Wenjun Cao ◽  
Jun Zha ◽  
Yaolong Chen
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Core Material ◽  
Disc Cutter ◽  
Honeycomb Core ◽  
Cutting Force Prediction ◽  
Paper Honeycomb ◽  
Ultrasonic Cutting ◽  
Core Materials

The disc-cutter is a finishing tool for the ultrasonic-cutting of paper honeycomb-core material. The cutting state directly affects the machining accuracy and surface quality of the workpiece. The cutting force is an important physical quantity and the cause of ultrasonic cutting defects of the honeycomb-core material. Due to differences in the mechanical properties and cutting performance of honeycomb-core materials and commonly used metal materials, existing metal-cutting-force models cannot be applied to the calculation of ultrasonic cutting forces in the processing of honeycomb-core materials. In response to this problem—combined with actual working conditions using the ABAQUS finite element analysis software—a finite element simulation model of the ultrasonic vibration-assisted cutting force of the disc-cutter on the honeycomb-core material was established, and the cutting curves and values were obtained. The experiment of ultrasonic vibration cutting of the disc-cutter proves that from the surface morphology of the honeycomb core, the milling-width has the greatest influence on the cutting force, and the cutting-depth has the smallest influence on the cutting force. The maximum error between the cutting force experimental results and the finite element simulation results under the same cutting conditions was 13.2%, which means that the established cutting-force finite element model is more accurate and can be used to predict the cutting in honeycomb ultrasonic vibration-assisted cutting-force value. Finally, based on the response surface method, a three-dimensional cutting force prediction model of the ultrasonic cutting honeycomb core of the disc-cutter was established by using the simulation model data. The results of this study can provide a useful basis for the improvement of cutting performance and processing efficiency in the processing of paper honeycomb-core materials.

scholarly journals A Novel Ultrasonic Trepanning Method for Nomex Honeycomb Core

2020 ◽  
Vol 11 (1) ◽  
pp. 354
Author(s):  
Dingyi Sun ◽  
Renke Kang ◽  
Yidan Wang ◽  
Jialin Guo ◽  
Zhigang Dong
Keyword(s):  
Theoretical Model ◽  
Ultrasonic Vibration ◽  
High Speed ◽  
Vertical Surface ◽  
Core Material ◽  
Honeycomb Core ◽  
Dimensional Error ◽  
Characteristic Structure ◽  
Nomex Honeycomb

The vertical surface is a common and typical characteristic structure among Nomex honeycomb core components. However, the conventional high-speed milling and ultrasonic cutting struggle to meet the high-quality machining requirements of a vertical surface. In this study, an ultrasonic trepanning method is proposed and a special ultrasonic trepanning tool is developed, aiming to improve the machining quality of the vertical surface. The trepanning quality of the vertical surface is further studied from the aspects of dimensional error and trepanning incision quality. Based on the kinematic characteristics of ultrasonic trepanning, a theoretical model of dimensional error in trepanning is established. Meanwhile, the influence of ultrasonic vibration on the trepanning process is analyzed, and the result shows that ultrasonic vibration significantly improves the equivalent elastic constant of the honeycomb core material. The theoretical model is proposed to predict the trepanning dimensional error, which is verified by experiment. The effectiveness of the ultrasonic vibration on the incision quality is verified by several experiments, and the quantitative analysis results demonstrate that ultrasonic vibration significantly improves the trepanning quality of the vertical surface.

Machining quality of high speed helical milling of carbon fiber reinforced plastics

2021 ◽  
pp. 095440622199673
Author(s):  
Adel Abidi ◽  
Sahbi Ben Salem ◽  
Mohamed Athmane Yallese
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
High Speed ◽  
Hole Diameter ◽  
Feed Speed ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Machining Quality ◽  
Fiber Reinforced Plastics

Among advanced cutting methods, High Speed Milling (HSM) is often recommended to improve the productivity and to reduce the costs of machining parts. As every cutting process, HSM is characterized by some defects like surface roughness and delamination are the main defects generated in composite materials. The aim of this experimental work is the studying of the machining quality of woven Carbon fiber reinforced plastics (CFRP) using the HSM technology. Experiments were done using different machining parameters combinations to make opened holes in CFRP laminates. This study investigated the effect of cutting speed, orbital feed speed, hole diameter on the delamination defect and surface roughness responses generated in the drilled holes. The design of experimental tests was generated using the approach of Central Composite Design (CCD). The characterization of these responses was treated with the Analysis of variance (ANOVA) and Response surface methodology (RSM). Results showed that the surface roughness is highly affected by the orbital feed speed (F) with contribution of 22.45%. The delamination factor at entry and exit of holes is strongly influenced by the hole diameter D (25.97% and 57.43%) respectively. The developed model equations gave a good correlation between the empirical and predicted results. The optimization of the milling parameters was treated using desirability function to minimize the surface roughness (Ra) and the delamination factor simultaneously.

Numerical Analysis and Mechanical Properties of Nomex™ Honeycomb Core

2017 ◽  
Author(s):  
Yue Liu ◽  
Weicheng Gao ◽  
Wei Liu ◽  
Zhou Hua
Keyword(s):  
Compressive Strength ◽  
Cell Walls ◽  
Mechanical Response ◽  
Compressive Loading ◽  
Fe Model ◽  
Honeycomb Core ◽  
Practical Applications ◽  
Honeycomb Sandwich ◽  
Nomex Honeycomb ◽  
Strength And Stiffness

This paper presents an investigation on the mechanical response of the Nomex honeycomb core subjected to flatwise compressive loading. Thin plate elastic in-plane compressive buckling theory is used to analyze the Nomex honeycomb core cell wall. A mesoscopic finite element (FE) model of honeycomb sandwich structure with the Nomex honeycomb cell walls is established by employing ABAQUS/Explicit shell elements. The compressive strength and compressive stiffness of Nomex honeycomb core with different heights and thickness of cell walls, i.e. double cell walls and single cell walls, are analyzed numerically using the FE model. Flatwise compressive tests are also carried out on bare honeycomb cores to validate the numerical method. The results suggest that the compressive strength and compression stiffness are related to the geometric dimensions of the honeycomb core. The Nomex honeycomb core with a height of 6 mm has a higher strength than that of 8 mm. In addition, the honeycomb core with lower height possesses stronger anti-instability ability, including the compressive strength and stiffness. The proposed mesoscopic model can effectively simulate the crushing process of Nomex honeycomb core and accurately predict the strength and stiffness of honeycomb sandwich panels. Our work is instructive to the practical applications in engineering.

Simulation System for Quality Prediction and Parameters Optimization when Machining Ceramics Die Material

2008 ◽  
Vol 53-54 ◽  
pp. 299-303
Author(s):  
Zong Wei Niu ◽  
Zhi Yong Li ◽  
F.F. Wang ◽  
Dian Zhu Sun
Keyword(s):  
Surface Quality ◽  
Intelligent System ◽  
Simulation System ◽  
Parameters Optimization ◽  
Quality Prediction ◽  
Machining Parameters ◽  
Machining Quality ◽  
Die Material ◽  
Process Database

A simulation system was developed to forecast machining quality and optimize grinding parameters for the machining of ceramic die material. The system can forecast the surface quality of machined ceramic die material with high precision, optimize machining parameters and analyze the dominant factors. Based on the process database, the simulation system is applicable to various machining methods. It can help to raise the automaticity for the machining of ceramic die material and develop the farther intelligent system.

Influences of Ultrasonic Assistance in High Speed Lapping of Nano ZTA Engineering Ceramic on the Surface Machining Quality

2007 ◽  
Vol 359-360 ◽  
pp. 355-359 ◽  
Author(s):  
Feng Jiao ◽  
Bo Zhao ◽  
Chuan Shao Liu ◽  
Xun Sheng Zhu
Keyword(s):  
High Speed ◽  
Chip Thickness ◽  
Surface Profile ◽  
Abrasive Material ◽  
Regular Surface ◽  
Surface Machining ◽  
Machining Quality ◽  
Engineering Ceramic ◽  
Precision Finishing

Ultrasonic aided high speed lapping with solid abrasive material was put forward aimed at the precision finishing of nano ZTA engineering ceramic. Through theoretical analysis and contrast lapping experiments, the influences of ultrasonic assistance on the surface machining quality were clarified. Research results show that the maximum undeformed chip thickness in ultrasonic aided lapping is smaller than that in conventional lapping under the same conditions; ultrasonic assistance is beneficial to enlarging the range of ductile lapping regime and improving the surface quality of nano ZTA ceramic; with the application of ultrasonic vibration, smaller surface roughness and more regular surface profile can be obtained.

Sign in / Sign up

Export Citation Format

Share Document