Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting

doi:10.1007/s11465-021-0631-9

Front. Mech. Eng.

2021, Vol. 16

Issue (2) : 285-297 https://doi.org/10.1007/s11465-021-0631-9

RESEARCH ARTICLE

Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting

Yidan WANG, Renke KANG, Yan QIN, Qian MENG, Zhigang DONG(

)

Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, China

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Abstract

Ultrasonic cutting with a disc cutter is an advanced machining method for the high-quality processing of Nomex honeycomb core. The machining quality is influenced by ultrasonic cutting parameters, as well as tool orientations, which are determined by the multi-axis machining requirements and the angle control of the cutting system. However, in existing research, the effect of the disc cutter orientation on the machining quality has not been studied in depth, and practical guidance for the use of disc cutters is lacking. In this work, the inclined ultrasonic cutting process with a disc cutter was analyzed, and cutting experiments with different inclination angles were conducted. The theoretical residual height models of the honeycomb core, as a result of the lead and tilt angles, were established and verified with the results obtained by a linear laser displacement sensor. Research shows that the residual height of the honeycomb core, as a result of the tilt angle, is much larger than that as a result of the lead angle. Furthermore, the tearing of the cell wall on the machined surface was observed, and the effects of the ultrasonic vibration, lead angle, and tilt angle on the tear rate and tear length of the cell wall were studied. Experimental results revealed that ultrasonic vibration can effectively decrease the tearing of the cell wall and improve the machining quality. Changes in the tilt angle have less effect than changes in the lead angle on the tearing of the cell wall. The determination of inclination angles should consider the actual processing requirements for the residual height and the machining quality of the cell wall. This study investigates the influence of the inclination angles of a disc cutter on the machining quality of Nomex honeycomb core in ultrasonic cutting and provides guidelines for machining.

Keywords Nomex honeycomb core disc cutter inclined ultrasonic cutting machining quality

Corresponding Author(s): Zhigang DONG

Online First Date: 10 May 2021 Issue Date: 15 June 2021

Cite this article:

Yidan WANG,Renke KANG,Yan QIN, et al. Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting[J]. Front. Mech. Eng., 2021, 16(2): 285-297.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-021-0631-9
https://academic.hep.com.cn/fme/EN/Y2021/V16/I2/285

Fig.1 Machined surface texture of a Nomex honeycomb core machined by ultrasonic cutting with a disc cutter.

Fig.2 Structure of a disc cutter.

Fig.3 Schematic of the inclined ultrasonic cutting of a Nomex honeycomb core with a disc cutter.

Fig.4 Experimental setup for the inclined ultrasonic cutting of a Nomex honeycomb core. (a) Inclined ultrasonic cutting platform and (b) profile measurement of the machined surface with a linear laser displacement sensor.

Fig.5 Schematic of the cutting process with a disc cutter.

Fig.6 Result of the machined surface of the honeycomb core measured by a linear laser displacement sensor. The different colors represent the height variation of the measured surface.

Fig.7 Machining defects on the machined surface of a Nomex honeycomb core.

Fig.8 Diagram of honeycomb core tearing defects.

Fig.9 Schematic of inclined ultrasonic cutting with a tilt angle. (a) Machined surface shape caused by a tilt angle and (b) residual height caused by a tilt angle.

Fig.10 Effect of the tilt angle on the residual height.

Fig.11 Schematic of inclined ultrasonic cutting with a lead angle. (a) Machined surface shape as a result of the lead angle and (b) residual height as a result of the lead angle.

Fig.12 Effect of the lead angle on the residual height.

Fig.13 Effect of ultrasonic vibration on the machining quality of the honeycomb core: (a) Without and (b) with ultrasonic vibration.

Fig.14 Effect of ultrasonic vibration on the tear rate and tear length of the cell wall.

Fig.15 Cutting trajectory of a point on the cutting edge of a disc cutter when cutting with and without ultrasonic vibration.

Fig.16 Partial diagram of a disc cutter cutting a honeycomb core: (a) Without and (b) with ultrasonic vibration.

Fig.17 Effect of the tilt angle on the machining quality of a Nomex honeycomb core.

Fig.18 Effect of the tilt angle on the tear rate and tear length of the cell wall.

Fig.19 Cutting trajectory of a point on the cutting edge of a disc cutter when cutting with a tilt angle.

Fig.20 Effect of the tilt angle on the tear length of the cell wall in the different cutting zones.

Fig.21 Effect of the lead angle on the machining quality of a Nomex honeycomb core.

Fig.22 Effect of the lead angle on the tear rate and tear length of the cell wall.

Fig.23 Cutting trajectory of a point on the cutting edge of a disc cutter when cutting with a lead angle.

Fig.24 Effect of the lead angle on the tear length of the cell wall in the different cutting zones.

a_e	Width of cut, mm
a_p	Depth of cut, mm
A	Ultrasonic vibration amplitude, μm
d	Diameter of the disc cutter, mm
f	Ultrasonic vibration frequency, kHz
h_λ	Residual height caused by the inclination angle, mm
$h λ t i l t$	Residual height caused by the tilt angle, mm
$h λ l e a d$	Residual height caused by the lead angle, mm
l_t	Tear length of the cell wall, mm
n	Spindle speed, r/min
r	Radius of the disc cutter, mm
t	Machining time, s
v_f	Feed speed, mm/s
α_n	Normal clearance angle, (° )
β_n	Normal wedge angle, (° )
γ_n	Normal rake angle, (° )
λ_tilt	Tilt angle, (° )
λ_lead	Lead angle, (° )

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