Mechanism of ultrasonic cutting aramid honeycomb using disc cutters with different blade shapes

IF 5.7 1区工程技术 Q1 ENGINEERING, CIVIL

Thin-Walled Structures Pub Date : 2025-04-24 DOI:10.1016/j.tws.2025.113370

Jialin Guo, Zhigang Dong, Mingye Wang, Heng Luo, Yidan Wang, Renke Kang, Jiansong Sun

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引用次数: 0

Abstract

Aramid honeycomb (AH), as a thin-wall structural material, with its excellent properties is gaining popularity in sandwich structures in aerospace, etc. Ultrasonic cutting (UC) using disc cutters (DCs) is an innovative technology for processing honeycomb materials. Multi-tooth disc cutter (MTDC) is a novel cutter with revolutionary structure. However, the tool-material contact state is complicated by the introduction of ultrasonic vibration (UV) and variations of tool structure, and the cutting mechanism is not clarified. To address the issue, the finite element method (FEM) was adopted and multi-scale FE models were formulated, including a model of micro-region UC to investigate the mechanism of the cutting edge interacting with the cell wall, and a model of UC porous honeycomb to explore cutting forces and the machining quality with different blade shapes and UC parameters. Cutting simulations and experiments were performed. It was found that the cutting force of MTDC was significantly lower than that of the DC owing to the intermittent cutting effect of the teeth, and the stress concentration at the tool tip could reduce the deformation of the cell wall. The machined surface of MTDC was predominantly fiber pull-out, whereas the DC were predominantly burrs, but more refined. Ultrasonic amplitude (UA) was the most significant for machining quality, and good machining quality can be obtained when the UA is 20 µm. But the effects on machining quality of spindle speed and feed rate were not significant. Additionally, under different cutting parameters, the cutting force of MTDC in the feed direction and in the axial direction were reduced by an average 63.4 % and 76.9 % respectively compared to that of the DC. This provides theoretical guidance for the design of cutting processes for two different tools and the optimization of the structure of MTDC.

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不同刀型圆盘刀超声切割芳纶蜂窝的机理

芳纶蜂窝材料作为一种薄壁结构材料，以其优异的性能在航空航天等领域的夹层结构中得到越来越广泛的应用。超声切割（UC）是一种利用圆盘刀具（DCs）加工蜂窝材料的创新技术。多齿盘式刀具是一种具有革命性结构的新型刀具。然而，由于超声振动的引入和刀具结构的变化，刀具与材料的接触状态变得复杂，切削机理不明确。为了解决这一问题，采用有限元方法，建立了多尺度有限元模型，包括研究切削刃与细胞壁相互作用机理的微区域UC模型，以及研究不同叶片形状和UC参数下切削力和加工质量的UC多孔蜂窝模型。进行了切削仿真和实验。研究发现，由于齿的间歇性切削作用，MTDC的切削力明显低于DC，刀尖处的应力集中可以减少细胞壁的变形。MTDC的加工表面以纤维拉出为主，而DC的加工表面以毛刺为主，但更为精细。超声振幅（UA）对加工质量影响最为显著，当UA为20µm时，加工质量较好。主轴转速和进给速度对加工质量的影响不显著。此外，在不同切削参数下，MTDC在进给方向和轴向方向的切削力比DC平均分别降低63.4%和76.9%。这为两种不同刀具的切削工艺设计和MTDC结构的优化提供了理论指导。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Thin-Walled Structures 工程技术-工程：土木

CiteScore

9.60

自引率

20.30%

发文量

801

审稿时长

66 days

期刊介绍： Thin-walled structures comprises an important and growing proportion of engineering construction with areas of application becoming increasingly diverse, ranging from aircraft, bridges, ships and oil rigs to storage vessels, industrial buildings and warehouses. Many factors, including cost and weight economy, new materials and processes and the growth of powerful methods of analysis have contributed to this growth, and led to the need for a journal which concentrates specifically on structures in which problems arise due to the thinness of the walls. This field includes cold– formed sections, plate and shell structures, reinforced plastics structures and aluminium structures, and is of importance in many branches of engineering. The primary criterion for consideration of papers in Thin–Walled Structures is that they must be concerned with thin–walled structures or the basic problems inherent in thin–walled structures. Provided this criterion is satisfied no restriction is placed on the type of construction, material or field of application. Papers on theory, experiment, design, etc., are published and it is expected that many papers will contain aspects of all three.