| As an excellent composite materials, NOMEX honeycomb materials play more and moreimportant role in aerospace, automotive and building field. The traditional high-speed milling islow efficiency, poor quality of the work piece surface, large amounts of dust, and environmentand life safety are not guaranteed. How to improve the processing efficiency and processingenvironment of honeycomb materials and how to meet the processing requirements of thecomplex and massive development trend of parts are always puzzle the major manufacturers. Forabove problems, the ultrasonic cutting technology is introduced into the NOMEX honeycombmaterial processing field. This paper is focused on the cutting spindle of the NOMEXhoneycomb material, developed a ultrasound cutting spindle which is used for the processing.This paper to the ultrasonic cutting spindle structural design for the study, the main contentis divided into seven parts as follow：In the first chapter, the structural characteristics and performance of NOMEX honeycombmaterial were described, its research status at home and abroad was summarized and thedevelopment of ultrasonic cutting technology was also introduced.In the second chapter, combined with the existing ultrasonic cutting spindle structuralfeatures and the ultrasonic cutting basic principle, a new type of ultrasonic spindle wasdeveloped,which can achieve automatic tool changer. And based on this way, designed twodifferent automatic tool changer equipment.In the third chapter, first the Five-axis technology working principle and features wereanalyzed, then the ultrasonic cutting spindle and A/C-axes bi-rotary milling head were combinedtogether realized ultrasonic spindle multi-axis swinging to meet the parts complex developmenttrend requirement.In the fourth chapter, based on ultrasonic cutting technology principle and features,comprehensive designed acoustic system which is the core component of the new type ofultrasonic spindle: the structure size of sandwich transducer with harmonic frequency20kHzwas designed according to the frequency equation; combined with the traditional analytic methodand four-end network method the overall dimensions of tapered transition-type ultrasonic hornwith harmonic frequency20kHz was calculated; based on the features of existing cutter and thestructural properties of NOMEX honeycomb material,two kinds of cutters were designed,whichsuitable for different working conditions. In the fifth chapter, the model and morph of two kinds of ultrasonic acoustic system wereanalyzed by means of finite element analysis software ANSYS Workbench, to provided atheoretical basis for the ultrasonic cutting spindle theoretical research and product development.In the sixth chapter, the amplitude of the cutters were measured by Laser DisplacementSensor in a measuring experiment. The results of the experiment shown that the maximumamplitude of the cutters were0.035mm and distributed in the outer edge of the tool, whichconsistent with the results of the analysis by ANSYS Workbench; By using infrared temperaturemeasuring instrument,the temperature of ultrasonic cutting spindle during operation weremeasured, the results shown that the temperature of ultrasonic cutting spindle changes wasstable during operation, no significant warming trend; By using the ultrasonic cutting spindle tocut the NOMEX honeycomb material for large numbers of cutting experiments and the chips ofthe material were analyzed, the results shown that the surface of chips were smooth, no burr, thephysical of the chips were continuous, almost no dust generated during processing, theprocessing environment was improved and met the processing requirement.In the seventh chapter, the main research content of the paper was summarized and furtherresearch on the ultrasonic cutting spindles which were used for cutting the NOMEX honeycombmaterials was discussed and prospected. |
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