Research On Design And Performance Of Ultrasonic Cutting Disc Tool For Absorbing Honeycomb Material

Wave-absorbing honeycomb materials have the advantages of high specific strength and high specific stiffness,and are widely used in many fields such as military and aerospace.The conventional high-speed milling of wave-absorbing honeycomb materials has problems such as high dust pollution,poor machining performance and low tool life.As an increasingly important processing method in the field of fibre-reinforced composite materials processing,ultrasonic vibration cutting has been applied to the cutting of aramid honeycomb materials and is now internationally recognised as the most efficient and clean processing method.This paper introduces ultrasonic vibration cutting technology and applies it to the cutting of wave-absorbing honeycomb materials.The acoustic vibration cutting tool is an important component of ultrasonic vibration cutting processing.As a cutting tool for absorbing honeycomb cores,its geometry and structural dimensions directly affect the machining accuracy,quality and efficiency of the absorbing honeycomb core workpiece.The ultrasonic vibration processing of wave-absorbing honeycomb materials places high demands on the performance of cutting tools,which must not only have the cutting performance of traditional tools,but also meet the performance requirements of ultrasonic vibration cutting.The current research on ultrasonic vibration cutting tools for wave-absorbing honeycomb materials is almost in a blank stage,and there is an urgent need to promote related work to solve the practical engineering application requirements.To this regard,this paper integrates the design theory of traditional tools with the design method of ultrasonic tools,and carries out research on the ultrasonic vibration cutting mechanism of tools for wave-absorbing honeycomb materials,and designs a new type of disc tool for ultrasonic vibration cutting of wave-absorbing honeycomb materials,which achieves high-quality and efficient cutting processing of wave-absorbing honeycomb materials.The main research work and results are as follows.1.The analysis of the mechanism of ultrasonic vibration cutting of wave-absorbing honeycomb materials with a circular knife is carried out.Firstly,based on the rectangular cutting process of the circular knife,the typical cutting attitude is analyzed,and the deflection equation and stress equation of the honeycomb cell wall under the transverse cutting load are established by applying the theory of small deflection of elastic thin plate,and the deformation characteristics and fracture characteristics of the honeycomb cell wall under the ultrasonic vibration cutting of the circular knife are analyzed;secondly,the kinematic analysis of ultrasonic vibration cutting of the circular knife is carried out,and the actual vibration of the circular knife on the wave-absorbing honeycomb material is analyzed.Finally,the ultrasonic vibration cutting force model of the disc cutter is established and numerical analysis of the model is carried out by MATLAB,and it is concluded that the frequency f and amplitude A are the key sensitive parameters in ultrasonic vibration cutting,which provide specific reference indexes for the design of ultrasonic tools later on.2.To carry out the material and profile structure design of ultrasonic vibration cutting disc cutter for wave-absorbing honeycomb materials.The material and contour structure of the disc cutter directly affect the vibration performance of the tool.Firstly,the performance requirements of the tool material for ultrasonic vibration cutting are analysed and the material for tool manufacture is preferably selected;secondly,the structural form and main structural parameters of the tool are initially determined by combining the characteristics of ultrasonic cutting posture and the design principle of the saw blade milling cutter.The energy density and bending stiffness evaluation parameters and analysis methods of the tool are introduced to study the influence of the main parameters such as outer diameter D1,thicknessh h and wedge angle θ on the ultrasonic vibration characteristics of the tool cross-sectional profile structure,and then the theoretical analysis results are simulated and verified by combining with ANSYS Workbench;finally the optimal tool cross-sectional profile structure parameters are derived.3.To carry out the analysis of the influence of the edge tooth element structure parameters of the circular cutter on the ultrasonic cutting performance of honeycomb cores.Firstly,based on the saw blade milling cutter design theory,the initial range of the three key design parameters of the front angle γ,rear angle α and tooth height H in the edge tooth element structure is initially determined,then a three-dimensional finite element model of the ultrasonic cutting absorbing honeycomb core of the disc cutter is established,and the cutting process of the tool is simulated and analyzed by using ABAQUS software,and the influence law of the three key parameters in the edge tooth element structure on the cutting force and cutting heat is derived,and finally the optimal The optimal design parameters of the cutting edge element are determined to ensure the vibration cutting performance of the tool from the design level of the tool.4.The design and construction of the experimental bench and the experimental research on the ultrasonic vibration cutting performance of typical edged disc knives.Firstly,the ultrasonic vibration cutting test bench was designed and constructed,and the cutting process planning and design of the absorbing honeycomb core parts and the vibration performance of the tool were tested.Secondly,the three typical edged disc cutters developed at the same time were subjected to experimental research on cutting forces and cutting heat under the same experimental conditions,and the experimental results were compared and analysed to conclude that the cutting performance of the serrated-edge disc cutter designed in the previous paper was optimal.In addition,an empirical equation for the cutting force of ultrasonic vibration cutting of wave-absorbing honeycomb cores with a serrated-edge disc cutter is established,and the relationship between amplitude A,depth of cut a_p and cutting force F is derived.A comparison between ultrasonic vibration-assisted cutting and normal cutting was also carried out,and the significant effect of amplitude A on the variation of cutting force and cutting heat under ultrasonic vibration-assisted cutting conditions was obtained.