Processing technologies for Nomex honeycomb composites (NHCs): A critical review

On account of the remarkable mechanical properties, SiCp/Al composites are extensively utilized in the aerospace industry, exhibiting a vast scope of applications. However, the extremely hard particle reinforcement leads to poor machining quality, high cutting resistance, and severe tool wear in traditional machining, resulting in poor machinability and difficulty in meeting the requirements for high surface quality and low damage. The processability of SiCp/Al composites has been enhanced through the implementation of ultrasonic vibration machining technology. An overview of the influence of ultrasonic vibration machining on the machining properties of SiCp/Al composites is presented in this study, covering different forms of ultrasonic vibration machining, vibration devices, and theoretical analysis, analyzing the intermittent separation behavior of tool and workpiece using cutting forces, surface topography, and tool wear as assessment criteria. The development direction of the multi-energy field ultrasonic vibration composite machining technology for SiCp/Al composites is also outlooked. The challenges of ultrasonic vibration technology in the fabrication of SiCp/Al composites include the theory of vibration propagation in non-uniform media, the theory of multi-energy field coupling, the design theory of vibration devices, and the microscopic removal mechanism of materials under ultrasonic energy impact. Therefore, theoretical breakthroughs and device improvements play an important role in future research on ultrasonic vibration machining of SiCp/Al composites. 

A comprehensive review of advances in ultrasonic vibration machining on SiCp/Al composites

Investigation on damage reduction method by varying cutting angles in the cutting process of rectangular Nomex honeycomb core

Bone has a special structure that is both stiff and elastic, and the composition of bone confers it with an exceptional mechanical property. However, bone substitute materials that are made of the same hydroxyapatite (HA) and collagen do not offer the same mechanical properties. It is important for bionic bone preparation to understand the structure of bone and the mineralization process and factors. In this paper, the research on the mineralization of collagen is reviewed in terms of the mechanical properties in recent years. Firstly, the structure and mechanical properties of bone are analyzed, and the differences of bone in different parts are described. Then, different scaffolds for bone repair are suggested considering bone repair sites. Mineralized collagen seems to be a better option for new composite scaffolds. Last, the paper introduces the most common method to prepare mineralized collagen and summarizes the factors influencing collagen mineralization and methods to analyze its mechanical properties. In conclusion, mineralized collagen is thought to be an ideal bone substitute material because it promotes faster development. Among the factors that promote collagen mineralization, more attention should be given to the mechanical loading factors of bone.

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Biomechanical Characteristics and Analysis Approaches of Bone and Bone Substitute Materials

Cracks generated in micro and meso-scales pose a potential threat to the full product. Numerous reports on microscale voids and cracks in Nomex honeycomb composites (NHCs) have focused on the process of co-curing and co-bond. Practically, substantial meso-scale cracks were introduced in the machining without sufficient attention. To fill this gap, the study explored a new phenomenon (i.e., transverse and longitudinal cracks) in meso-scales, with a special focus on formation mechanism and evolution. A meso-scale numerical model of NHCs was developed for the analysis of fracture inducing mechanisms in ultrasonic vibration machining (i.e., multi-source loading conditions). During model establishment and validation, not only the friction model of the cutter and NHCs was amended, but also the cutting force system was evaluated and compensated. Analytical and experimental validation indicated that the cell deformation and the peak value of the cutting force showed a reasonable agreement with the numerical results. Further understanding based on the numerical model can obtain the cracks initiation mechanisms that: (i) Transverse cracks are induced by longitudinal tensile stress, which is generated by tool vibration, while (ii) longitudinal cracks are induced by transverse tensile stress, which is caused by tool feed. The findings of meso-scale cracks not only enhance the significance of curing-induced microcracks and voids, but also provide theoretical guidance for the evolution of macroscopic defects after machining. 

Meso-scale cracks initiation of Nomex honeycomb composites in orthogonal cutting with a straight blade cutter

Nomex honeycomb core materials have been widely used in the aviation industry due to their special structure and performance. Conventional high-speed machining have resulted in the poor machinability of the honeycomb core so that the ultrasonic machining technology was applied. The kinematic characteristics in the ultrasonic vibration assisted cutting process were analyzed according to the movement of the sharp tool. Based on slide effect, a cutting force model was proposed to study the relationship between cutting parameters and cutting force. Ultrasonic vibration assisted cutting and ordinary cutting tests of Nomex honeycomb core material were conducted by considering feed rate, the inclined angle and the deflected angle. Besides, the effects of cutting parameters on machined surface quality of honeycomb core wall were studied. The test results show that slide effect caused by ultrasonic vibrations can reduce cutting resistance compared with ordinary cutting. The developed cutting force model can be applied to evaluated the cutting force in the ultrasonic vibration assisted cutting of Nomex honeycomb core material. The inclined angle has a great influence on the cutting force during ultrasonic vibration assisted cutting. High-speed reciprocating sliding action can effectively cut aramid fibers so that burrs and tearing defects of the incision have been greatly improved under condition of ultrasonic vibration assisted cutting.

Ultrasonic Vibration Assisted Cutting of Nomex Honeycomb Core Materials

SiCp/Al composites have been widely used in many fields due to their excellent mechanical properties. However, the addition of reinforced phase SiC particles makes the overall properties of the composites hard and brittle, which brings great challenges to milling. Ultrasonic vibration-assisted processing technology has great advantages in processing hard and brittle materials. However, the process of rupture of SiC particles cannot be effectively observed during the test processing, and a large number of tests increase the cost of the test. The combination of finite element analysis and experiment was used to study the machining performance of High-volume fraction SiCp/Al composites in longitudinal-torsional ultrasonic-assisted milling (LTUAM), and its feasibility was evaluated by comparing with conventional Milling (CM). By analyzing the trajectories of cutting edges in ultrasonic-assisted milling, It was found that ultrasonic frequency determines the time of periodic contact-separation between chisel edge and workpiece, and ultrasonic amplitude determines the maximum distance of contact-separation. Using ABAQUS finite element software, a polygon SiC particles model with a high-volume fraction was established to investigate the SiC particles crushing process under different ultrasonic-assisted milling conditions. The results showed that high-frequency ultrasonic-assisted milling could soften SiCp/Al composites, and the structural integrity of silicon carbide particles could be better maintained under appropriate ultrasonic amplitudes, reducing the probability of fragmentation. The removal mode was mainly plastic removal or crushing into small particles. The surface roughness value and milling force were reduced, improving the surface quality of the processed composite material. The conclusions of the milling test were basically consistent with the simulation results, which prove the correctness and feasibility of the simulation results.

Finite Element and Experimental Analysis of Ultrasonic Vibration Milling of High-Volume Fraction SiCp/Al Composites

Silicon carbide particle-reinforced aluminum matrix composite has been widely used in the military and aerospace industry due to its special performance; however, there remain many problems in processing. The present paper introduces an ultrasonic vibration tensile device with a view to investigating an ultrasonic vibration tensile specimen. The results show that there are three major stages in the change in stress of the material under ultrasonic vibration: the ultrasonic stress superposition effect, softening effect, and Hall–Petch strengthening effect, these three effects occupy different proportions in different tensile stages. In addition, increasing the frequency of ultrasonic vibration increased the degree of stress reduction. Increasing the ultrasonic vibration amplitude reduced the fracture strength of the material. Comparison of the fracture morphology shows that the conventional condition was mainly interfacial peeling of SiC particles, and cleavage of the fracture occurred under ultrasonic vibration conditions.

Effect of Ultrasonic Vibration Tensile on the Mechanical Properties of High-Volume Fraction SiCp/Al Composite

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Papers

Ultrasonic Vibration Assisted Cutting of Nomex Honeycomb Core Materials

Finite Element and Experimental Analysis of Ultrasonic Vibration Milling of High-Volume Fraction SiCp/Al Composites

Effect of Ultrasonic Vibration Tensile on the Mechanical Properties of High-Volume Fraction SiCp/Al Composite