Study On Design And Cutting Performance Of Honeycomb Composites Ultrasonic Cutting Tool

NOMEX honeycomb core composite material with high specific strength,low density,corrosion resistance,fatigue resistance,good thermal stability,excellent insulating properties and a series of characteristics.The material is usually made of sandwich structure,and is widely applied in the aerospace field.The traditional method of high-speed cutting in the processing of honeycomb material,the presence of processing poor quality,low processing efficiency,poor working environment and other shortcomings.Ultrasonic cutting technology in recent years as the rise of a new processing technology,which has a large advantage in the processing of cellular materials.Ultrasonic cutting tool is used as the executive component in ultrasonic machining of honeycomb material,its structure size and geometry shape directly affect the machining quality and precision of the material.The disc cutting tool was used for NOMEX honeycomb core ultrasonic cutting finishing stage.In the paper,a three-dimensional finite element model of the disk cutting tool with ultrasonic machining for NOMEX honeycomb is established and the influence of the tool rake angle,tool clearance angle and blade diameter on the feeding force and the cutting temperature is studied.The results show the feeding force increases with increasing of tool rake angle and blade diameter,but decreases with increasing of the tool clearance angle.The cutting temperature increases with increasing of tool rake angle and blade diameter,but decreases with increasing of tool clearance angle.The blade knife was used for NOMEX honeycomb core ultrasonic cutting roughing stage.A three-dimensional finite element model of the coupled thermal and mechanical analysis for the ultrasonic cutting of NOMEX honeycomb is established,and design blade knife ultrasonic cutting NOMEX honeycomb core test to verify the correctness of the simulation model.The influence of the cutting edge angle,cutting tool length and thickness on the feeding force and the cutting temperature is researched with single factor method.The results show that the feeding force and cutting temperature decrease with the increasing of cutting tool length,but increase with the increasing of cutting tool thickness and cutting edge angle.And a mathematical model on the feeding force and cutting temperature during honeycomb core cutting was built.The influence of cutting parameters on the feed force and the cutting temperature was further explained.According to the influence of tool parameters on disc cutting tool and blade knife,the two knife was designed to optimize the structure size.Optimization results show that the optimization of disc cutter and straight blade knife in the feed force were reduced by 28%and 25%,and in the cutting temperature were decreased by 4.6%and 7%...