Yuan Xinman, Zhang Kexin, Zha Huiting, Xu Jie, Song Ge, Cao Wenjun, Feng Pingfa, Feng Feng
AVIC Chengdu Aircraft Industrial (Group) Co., Ltd., Chengdu 610073, China.
Division of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, China.
Materials (Basel). 2023 Aug 13;16(16):5611. doi: 10.3390/ma16165611.
Machining Nomex honeycomb composites (NHCs), which are widely-used materials in the aerospace industry, is an imperative process to obtain desired profiles. However, when machining NHCs to obtain a thin-edged surface, some problems can arise due to large cutting forces. To avoid these defects, a method of ultrasonic vibration machining with variable angles of the down milling disc cutter was proposed in this study. The processing principles and motion characteristics of this method were elaborated. A theoretical model of its cutting process was established. The principle of cutting force reduction was qualitatively analyzed based on the model, and an experimental validation was conducted. The results demonstrated that, due to a smaller swing angle in each pass, the proposed method could reduce the fractal dimension of the machined surface by 6.01% compared to 1° with 10° of angle in each pass. And severe machining defects were decreased. Additionally, comparing the process of the fixed 10° angle of ultrasonic vibration machining with the process of a 1° angle in a pass, cutting force can be significantly reduced by 33.5%, demonstrating the effectiveness of the proposed method which improved surface quality by reducing cutting forces.
加工诺梅克斯蜂窝复合材料（NHCs）是获得所需型材的必要工艺，该材料在航空航天工业中广泛使用。然而，在加工NHCs以获得薄边缘表面时，由于切削力较大，可能会出现一些问题。为避免这些缺陷，本研究提出了一种下铣圆盘铣刀角度可变的超声振动加工方法。阐述了该方法的加工原理和运动特性。建立了其切削过程的理论模型。基于该模型对切削力降低原理进行了定性分析，并进行了实验验证。结果表明，由于每次走刀的摆动角度较小，与每次走刀角度为10°、固定为1°相比，该方法可使加工表面的分形维数降低6.01%。并且减少了严重的加工缺陷。此外，将超声振动加工固定10°角的过程与一次走刀1°角的过程进行比较，切削力可显著降低33.5%，证明了该方法通过降低切削力提高表面质量的有效性。
