Sun Jiansong, Dong Zhigang, Wang Xuanping, Wang Yidan, Qin Yan, Kang Renke
Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, People's Republic of China.
Ultrasonics. 2020 Apr;103:106102. doi: 10.1016/j.ultras.2020.106102. Epub 2020 Jan 30.
Aluminum honeycomb has been widely used in many industrial fields, especially the aeronautics and aerospace industries, owing to its high strength and stiffness to weight ratio. Machining of aluminum honeycomb is usually associated with deformations and burrs. Ultrasonic cutting has been introduced as a promising method to overcome these constraints. In order to conduct in-depth research on the ultrasonic cutting for aluminum honeycomb by disc cutter, a 3D finite element model is carried out and verification tests are performed. Comparison result of simulated and experimental cutting forces indicates that the developed model agrees well with the experiment. Based on the developed model, cutting forces and contact relationship between cutter and honeycomb during the cutting process are studied. The reason for the periodic increase in cutting force is analyzed, subsequently. Moreover, the stress distribution in the cutting zone and honeycomb morphologies under different cutting conditions are compared and analyzed. Results show that the hexagonal structure of aluminum honeycomb can be protected and machining quality can be improved by using ultrasonic vibration. Therefore, high quality and efficient machining for aluminum honeycomb can be achieved.
铝蜂窝由于其高强度和高刚度重量比，已在许多工业领域广泛应用，尤其是在航空航天工业中。铝蜂窝的加工通常会产生变形和毛刺。超声切割作为一种有前景的方法被引入以克服这些限制。为了对盘形刀具超声切割铝蜂窝进行深入研究，建立了三维有限元模型并进行了验证试验。模拟和实验切削力的比较结果表明，所建立的模型与实验结果吻合良好。基于所建立的模型，研究了切削过程中的切削力以及刀具与蜂窝之间的接触关系。随后分析了切削力周期性增加的原因。此外，还比较和分析了不同切削条件下切削区的应力分布和蜂窝形态。结果表明，利用超声振动可以保护铝蜂窝的六边形结构并提高加工质量。因此，可以实现铝蜂窝的高质量高效加工。
