A force-insensitive impedance compensation method for giant magnetostriction ultrasonic cutting system of Nomex honeycomb composites

The Nomex honeycomb core has been widely used in many industrial fields, especially the aircraft and aerospace industries, due to its high strength and stiffness to heaviness ratio. Machining of the Nomex honeycomb structure is usually associated with tearing of the walls, deformations of the cells and the appearance of burrs. Therefore, milling of the Nomex honeycomb structure represents an industrial hurdle challenge for scientists and researchers about the quality of the machined surface and the integrity of the cutting tool. In response to this problem, we have developed a three-dimensional numerical model of finite elements based on the real conditions of experimental work by means of the analysis software Abaqus. Based on the developed numerical model, an experimental validation was performed by comparing the quality of the surface and the adhesive wear of the cutting tool determined from the numerical simulation and that established by the experiment. In addition, the effect of geometric parameters in terms of wedge angle and cutting tool diameter on material accumulation, chip size, generated surface and cutting forces was analyzed. The results of the quantitative analysis prove that the choice of cutting conditions and cutting tool geometry in terms of favorable rake angle and tool diameter improves the surface quality of the generated part and optimizes the integrity of the cutting tool.

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Simulated Study of the Machinability of the Nomex Honeycomb Structure

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.

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

Aramid honeycomb has extensive applications in the aerospace and rail transportation industries. Ultrasonic cutting (UC) with the straight blade (SB) is an advanced technology used for the profile machining of honeycomb materials. Cutting force is an important factor affecting machining quality, and its accurate modelling is particularly important. However, SB is a flake tool, and chips of honeycomb are removed in block or strip forms during cutting, and its structure and material removal method are obviously different from conventional machining. Existing simplified cutting force models based on kinematic analyses and experiments are incapable of describing the cutting process. In this paper, a geometrical kinematics analysis of SB is conducted. Further, the modelling of tool-workpiece contact rate (TWCR) for UC with SB is established, which is utilized to analyze the tool-material contact state. Based on the principle of conservation of energy, the fracture force at the blade edge is analyzed. Based on the analysis of instantaneous friction force, the friction force model at tool surfaces is established. Multiple-cutting experiments are conducted to separate fracture force and friction force. The influence of machining parameters (ultrasonic amplitude, lead angle, cutting speed) on TWCR, cutting force, fracture force, and friction force have been theoretically and experimentally studied, and the reduction mechanism of the cutting force is revealed. Furthermore, the machining quality under different machining parameters is observed and the relationship with cutting force is analyzed. The paper not only provides theoretical guidance for the study of the UC mechanism but also helps to guide the UC process of aramid honeycomb. 

Cutting Force Reduction Mechanism in Ultrasonic Cutting of Aramid Honeycomb


 In ultrasonic processing technology applications, the force load can cause a drift in the resonance frequency of the ultrasonic transducer and significantly reduce its mechanical quality factor. The traditional equivalent circuit of an ultrasonic transducer can only be used to calculate performance parameters without a force load but not with a force load. Based on Mason’s equivalent circuit, a new equivalent circuit for ultrasonic transducers under a force load is derived while considering the effects of the force load on the material parameters and various types of losses in piezoelectric ceramics. Furthermore, performance parameters are analyzed, such as the resonance frequency, effective electromechanical coupling coefficient, and mechanical quality factor. The ultrasonic transducer sample is produced and the experimental platform is constructed for applying force loads on the ultrasonic transducer. The theoretical model is verified by static loading on the ultrasonic transducer. The proposed equivalent circuit provides theoretical guidance for tracking the exact resonance frequency and performance parameters of force-loading ultrasonic transducers.

Investigation of the equivalent circuit and performance of an ultrasonic transducer under a force load

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.

A Novel Ultrasonic Trepanning Method for Nomex Honeycomb Core

The invention discloses an ultrasonic cutting method for a honeycomb core settling tank structure. The ultrasonic cutting method includes the following steps of S1, contour forming processing, S2, block dividing processing, S3, honeycomb core settling tank structure internal material removing processing, and S4, honeycomb core settling tank structure bottom face finish processing. Ultrasonic cutting is adopted, a traditional honeycomb core cutting mode is changed, processing defects caused by traditional cutting are avoided, and processing quality and processing efficiency of the honeycomb core settling tank structure are improved.

Ultrasonic cutting method for honeycomb core settling tank structure

The invention discloses an amplitude-change pole for a honeycomb core ultrasonic cutting system. The amplitude-change pole is characterized by comprising an amplitude-change pole inner cooling connection screw, an ultrasonic cutting amplitude-change pole connection base, a rapid changing type ultrasonic cutting amplitude-change pole core and an ultrasonic cutting knife. From the fact of ultrasoniccutting, the requirements of high-quality and high-efficiency machining for honeycomb core ultrasonic cutting are met, the amplitude-change pole has the advantages of being convenient to disassemble,high in interchangeability and the like, and the honeycomb core ultrasonic cutting machining efficiency and automatic level can be improved.

Amplitude-change pole for honeycomb core ultrasonic cutting system

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A Novel Ultrasonic Trepanning Method for Nomex Honeycomb Core

Ultrasonic cutting method for honeycomb core settling tank structure

Amplitude-change pole for honeycomb core ultrasonic cutting system