Research On Cutting Force Modeling And Tool Design Of Ultrasonic Cutting NOMEX Honeycomb Core Material

At present,many scholars have studied the excellent properties of NOMEX honeycomb composites,NOMEX honeycomb composites have been applied to various fields,such as aerospace,automobile,ship and radar manufacturing,so that the demand for NOMEX honeycomb composites is greatly increased.Because the NOMEX honeycomb materials have weak stiffness in the surface,the traditional machining methods will cause some defects,such as cell element collapse.So the traditional machining methods can't achieve the high quality and high efficiency machining of the NOMEX honeycomb core material.Two kinds of machining methods are widely used at present,high speed milling and ultrasonic cutting.Considering that ultrasonic machining has the advantages in high processing efficiency,high surface quality and environmental protection,ultrasonic cutting NOMEX honeycomb composites have gradually become the focus of research.However,the research on the cutting mechanism of ultrasonic cutting NOMEX honeycomb core materials has not yet formed a systematic and perfect theory.In this paper,the average cutting force model of ultrasonic cutting NOMEX honeycomb core is studied and perfected,and the ultrasonic cutting experiment of NOMEX honeycomb material is carried out.The reasonableness of the designed straight edge tool and the established mechanical model is verified.The main contents of this paper include:(1)The excellent properties,application fields and processing methods of NOMEX honeycomb composites are studied.The advantages of ultrasonic cutting technology in the machine of NOMEX honeycomb core are analyzed,and the research status of ultrasonic cutting NOMEX honeycomb core materials is summarized,and the purpose and significance of the research are clarified.(2)According to the needs of ultrasonic cutting NOMEX honeycomb core materials,a straight edge tool is designed to meet the requirements of the experiment The tool structure size is optimized with the ANSYS WORKBENCH software,and the harmonic response analysis of the optimized cutter is carried out,and the rationality of the design and optimization is verified.(3)The mechanical properties and the equivalent parameters of the NOMEX honeycomb core materials are analyzed and studied.The main equivalent parameters which is required by the numerical simulation of ultrasonic cutting NOMEX honeycomb core are obtained.(4)The dynamic analysis of ultrasonic cutting NOMEX honeycomb core material is carried out.The mechanical model of the average cutting force for ultrasonic cutting NOMEX honeycomb core is established,and the numerical simulation analysis is carried out by using MATLAB software to study the relationship between the cutting force and the cutting parameters.(5)The experimental analysis of ultrasonic cutting NOMEX honeycomb core was carried out by using the designed cutting tool.The rationality of the designed tool and the established mechanical model was verified.Micro mirror is used to measure and analyze the cutting surface quality,and the relationship between cutting parameters and cutting surface quality is verified.