Research On Low-temperature Ultrasonic Cutting Technology Of Honeycomb Styrofoam

The honeycomb panel has wide applications in the aerospace field due to its superior comprehensive performance,and the styrofoam plays an important role in splicing,filling and fixing of honeycomb panel structure.When using sheet styrofoam,it needs to be cut into small strips with specified shape,size and accuracy in advance.However,styrofoam is soft and viscous at room temperature.Styrofoam is easily to stick the knife,and the incisions are easily deformed and adhered to each other when cutting by conventional mechanical methods,which are difficult to ensure the cutting accuracy and cutting efficiency of styrofoam.These problems limit the processing quality and processing efficiency of honeycomb panels.In this paper,based on the bonding principle of styrofoam,the technology of ultrasonic cutting combined with low-temperature processing is proposed to improve the cutting process of styrofoam.The specific research contents are as follows:(1)The ultrasonic cutting tool of styrofoam was designed.From the point of view of reducing the contact pressure and micro contact area between the blade and the styrofoam to prevent styrofoam sticking knife.The 30 kHz ultrasonic transducer and 30 kHz ultrasonic horn were designed.The resonance frequency and modal shape of ultrasonic transducer and horn were simulated by ANSYS modal analysis.Using the tip angle and blade angle as variable parameters,nine straight-edge tip cutting blades with different size parameters were designed.The effects of blade size parameters on the resonance frequency and the tip temperature of the ultrasonic tool were studied by a combination of simulation and experiment.According to the research law,the ultrasonic cutting blade with appropriate size parameters was finally determined,and the design of the ultrasonic cutting tool was completed.(2)An automatic cutting motion platform of styrofoam was built.The three-dimensional four-axis motion platform was designed,which can realize the stable cutting of the styrofoam in a large range.The installation mode of ultrasonic tool spindle was designed,which can ensure the high spindle centering accuracy,and ensure that the direction of blade is consistent with the feed direction when the tool is installed so that the blade can cut the styrofoam effectively.After comparing the comprehensive performance of various materials and cutting the materials,PE board was selected as the chopping board material to design the styrofoam cutting board.The motion control system of the cutting platform was designed and the stepper motor,stepper motor driver,control host and motion controller of the linear module were selected.The circuit diagram of the motion control system was designed and the electric control box was made.The motion control system can automatically cut the styrofoam according to the CAD drawing imported into the control host.(3)A low-temperature cutting system of styrofoam was designed and the low-temperature cutting experiment of styrofoam was carried out.From the point of view of reducing the contact temperature between the blade and the styrofoam,the fluidity and the molecular activity of the styrofoam to prevent styrofoam sticking knife and prevent incisions sticking to each other.From the point of view of improving the hardness of styrofoam to enhance its deformation resistance.Firstly,the working condition of the refrigeration system was calculated according to the refrigeration target of-10°C.The key components such as compressor,condenser,evaporator and capillary were calculated,designed and selected.The electrical control scheme of the refrigeration system was designed,which can set and control the refrigeration temperature.Then the performance of the refrigeration system was tested,and the results showed that the refrigeration system had a cooling capacity of-10℃.At the same time,the refrigeration process was smooth and windless,without blowing out the styrofoam strips.Finally,the experiment of low-temperature ultrasonic cutting of styrofoam was carried out.It was found that when the temperature was-5℃,the ultrasonic cutting tool had a good cutting effect on the styrofoam,which verified the practicability and effectiveness of low-temperature ultrasonic cutting technology of styrofoam.