ArcSaw – A new tool for rapid machining of sculpted surfaces in aramid honeycomb

A novel cutting tool, called the ArcSaw, is proposed, developed, and tested to address the high cost and long cutting times for aramid honeycomb sculpted surfaces. The tool utilizes a circular or elliptical band of cutting teeth to quickly remove large quantities of aramid honeycomb in a roughing process. The band, simulating a very-large radius ball end mill, can remove large quantities of honeycomb in a very short timeframe. However, instead of shredding all of that aramid into dust, as is done with current roughing cutters, this process removes the material in strips which pose a much-reduced risk to the machine’s moving parts, the operator’s lungs, and general facility cleanliness. In the development of the process, a simple FEA model was developed to help with an understanding of the process, the effect of cutting tooth spacing, and the magnitude of cutting forces. This model was compared with preliminary cutting tests on a traditional bandsaw using high speed videography and a force dynamometer. Once the ArcSaw prototype design was completed, an ArcSaw was mounted in a vertical machining center and used in a cutting test. Despite some challenges with out-of-round blades, the results of the cutting test were shown to have reasonable agreement with the FEA analysis. Strengths and opportunities for improvement of the ArcSaw design were catalogued.