Simulated and Experimental Study on the Ultrasonic Cutting Mechanism of Aluminum Honeycomb by Disc Cutter

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.

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Experimental Study on Rock Cutting by Use of Actual Size Disc Cutter with Round Tip

Modern Tunneling Science and Technology ◽

10.1201/9780203746653-104 ◽

2017 ◽

pp. 599-604

Author(s):

H. Takahashi ◽

T. Sato ◽

H. Yamanaka ◽

K. Kaneko ◽

K. Sugawara

Keyword(s):

Experimental Study ◽

Rock Cutting ◽

Disc Cutter ◽

Actual Size

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Ultrasonic Cutting with High-Gain Blades

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.1-2.45 ◽

2004 ◽

Vol 1-2 ◽

pp. 45-50

Author(s):

Alan MacBeath ◽

Andrea Cardoni ◽

Lorna Smith ◽

Margaret Lucas

Keyword(s):

Longitudinal Mode ◽

Compact Tension ◽

High Gain ◽

Long Bone ◽

Ultrasonic Frequency ◽

Cutting Mechanism ◽

Gain Profile ◽

The Relationship ◽

Cutting Experiments ◽

Ultrasonic Cutting

The design of high power ultrasonic cutting devices is based on tuning a blade to a longitudinal mode of vibration at a low ultrasonic frequency, usually in the range 20-100 kHz. To achieve the required cutting amplitude, gain is designed into the blade via profiling. It is expected that the use of higher-gain blades could enable longitudinal-mode guillotine-type cutting of a range of materials traditionally difficult to cut using this technology. Using a conventional high-gain blade, a feasibility study of ultrasonic cutting of bone is conducted using compact tension specimens of bovine femur. Finite element (FE) models are created, based on the assumption that the ultrasonic blade causes a crack to propagate in a controlled mode 1 opening. The models are compared with the experimental data collected from ultrasonic bone cutting experiments. Although the proposed cutting mechanism is supported by the data, the blade gain is insufficient to enable through cutting of long bone or other difficult to cut materials. Consequently, the paper examines the relationship between gain, profile, stress and nodal position for a range of ultrasonic cutting blades with increased gain.

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