Sun Jiansong, Qin Yan, Xing Wei, Kang Renke, Dong Zhigang, Wang Yidan
State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology, No. 2, Linggong Road, Dalian, Liaoning Province, 116024, China.
State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology, No. 2, Linggong Road, Dalian, Liaoning Province, 116024, China.
Ultrasonics. 2024 Dec;144:107444. doi: 10.1016/j.ultras.2024.107444. Epub 2024 Aug 27.
Aluminum honeycomb sandwich structure has been widely used in the aeronautic and astronautic fields. As the core part, aluminum honeycomb needs to be machined but defects are easily generated. Ultrasonic cutting is an advanced machining technology for honeycomb materials due to improved machining quality. However, ultrasonic cutting aluminum honeycomb by straight-blade knife is usually accompanied by cell wall deformation, which results in poor machining quality. To facilitate the industrial use of ultrasonic cutting aluminum honeycomb with a straight-blade knife, a finite element (FE) model was developed, and experimental studies had been performed. The effects of the blade-inclined angle and lead angle of the straight-blade knife were studied by analyzing the cutting force, the stress and deformation in the cutting zone. Results showed that the cell wall deformation was significantly suppressed when cutting with a corresponding blade-inclined angle and a lead angle. Meanwhile, effects of ultrasonic cutting parameters on the cell wall deformation were also studied, indicating that a well-machined cell wall could be obtained when cutting with large ultrasonic amplitude.
铝蜂窝夹层结构已在航空航天领域得到广泛应用。作为核心部件，铝蜂窝需要进行加工，但容易产生缺陷。超声切割由于能提高加工质量，是一种用于蜂窝材料的先进加工技术。然而，用直刃刀具超声切割铝蜂窝时通常伴随着胞壁变形，这导致加工质量较差。为便于直刃刀具超声切割铝蜂窝在工业上的应用，建立了有限元（FE）模型，并进行了实验研究。通过分析切削力、切削区的应力和变形，研究了直刃刀具的刃倾角和超前角的影响。结果表明，采用相应的刃倾角和超前角进行切割时，胞壁变形得到了显著抑制。同时，还研究了超声切割参数对胞壁变形的影响，结果表明，采用较大的超声振幅进行切割时，可以获得加工良好的胞壁。
