High-speed Milling Analysis And Numerical Simulation For Honeycomb Material

According to their unique geometric structures, honeycomb cores have much better specific strength and specific stiffness than regular materials, which makes honeycomb core widely used in the fields of aerospace, watercraft, transportation, architecture, sports, etc. In addition, NOMEX honeycomb core has the specific character of voice, heat and electricity resistance so that it is used extensively for essential aircraft parts, for example internal wall of planes, radome, isolation layer, etc. Nickel based alloy honeycomb core is the main material for combustion chamber of engines since it can work under extremely high temperature. In order to solve the problems during honeycomb core milling process, such as low efficiency, poor quality and unpredictable machining parameters, this paper combined the theories of high speed machining and finite element method to analysis the influence laws on how machining parameters affect cutting force and surface quality from both theoretical and experimental ways.The paper systematically studies the simulation method for high speed milling of NOMEX and nickel based alloy honeycomb core. Based on the plastic deformation mechanism of composite materials and difficult-to-cut metals, the paper deeply analyzes the key technologies of FEM simulation, for instance constitutive relations of materials, contact property of cutter and chips, material failure criteria and so on. Three dimensional models for honeycomb core high speed milling is established using ABAQUS software, which provides a way to investigate the influence laws of machining parameters.High speed milling experimental platforms for NOMEX and nickel based alloy honeycomb material are established respectively, milling processes under different parameters are approached, and the cutting forces in three dimensions are measured and analyzed. Furthermore, machined surfaces are screened using super depth of field3-D microscope.This paper provides considerable values of theoretical reference and realistic guidance on the determination of machining parameters for high speed milling of NOMEX and nickel based alloy honeycomb core.