Study On Milling Force Prediction Of Aluminum Honeycomb Core

Compared with traditional metal materials,the aluminum honeycomb core not only has the characteristics of the metal material,but has the excellent spatial geometric and mechanical properties of the honeycomb material,such as light weight,high specific strength,high specific stiffness,energy absorption and shock absorption.It is widely used in aerospace,high-speed trains,radar detection and other fields.However,as it has high rigidity in the direction of the mandrel,the in-plane rigidity perpendicular to the mandrel is weak,the aluminum honeycomb core material.The effect of the milling force on each aluminum honeycomb wall is different,and defects such as tearing burrs,collapse,deformation of the honeycomb wall,and degumming will occur during the cutting process.This greatly limits the application range of aluminum honeycomb core materials.In this paper,starting from the aluminum honeycomb wall milling force,based on the classic cutting theory,the contact between the milling tool and the aluminum honeycomb wall is analyzed,and a prediction model of the aluminum honeycomb wall milling force is established.Orthogonal cutting tests and single wall milling experiments were carried out to complete the calibration of the cutting force coefficient and the verification of the aluminum honeycomb wall milling force model.Based on the aluminum honeycomb wall milling force model,analyze the contact between the milling tool and the aluminum honeycomb walls,establish the aluminum honeycomb core milling force prediction model.and verify the correctness of the model through the aluminum honeycomb core milling experiment.In order to study the defect formation mechanism of the aluminum honeycomb core provides a theoretical basis.The main research contents are as follows:(1)Based on the classic cutting theory,analyze the contact relationship between the milling tool and the aluminum honeycomb wall,use the thin wall milling angle to characterize the angle relationship of the cutting speed and the honeycomb wall,and use the number of cutting edges to characterize the milling tool at different depths during the cutting process The contact length with the aluminum honeycomb wall.The aluminum honeycomb wall milling force model including the thin wall milling angle and the number of cutting edges is established.(2)Through the orthogonal cutting test,the functional relationship between the deformation coefficient,the friction angle and the cutting parameters was fitted,the influence law of the cutting parameters on the friction angle and the deformation coefficient was explored,and the calibration of the cutting force coefficient was completed.It is found that the average error between the experimentally determined milling force and the theoretically predicted milling force was 9.25% by single wall milling experiment,which verified the correctness of the aluminum honeycomb wall milling force prediction model.Based on the prediction model,the influence of thin wall milling angle and cutting parameters on single wall milling force is further discussed.(3)Established a coordinate transformation matrix to transform the wall milling force of the aluminum honeycomb core,analyzed the contact relationship between the milling tool and each the aluminum honeycomb wall during the milling process,and divided the contact into several stages according to the relationship between the milling tool diameter and the length of the aluminum honeycomb wall,The thin wall milling angle of the milling tool contacting the aluminum honeycomb core at each stage was solved,and then the aluminum honeycomb core milling force prediction model was established.Through the aluminum honeycomb core milling experiment,it was found that the average error between the experimental milling force and the theoretical milling force was 15.17%.The aluminum honeycomb core milling force model can predict the milling force when milling the aluminum honeycomb core.