Development Of Ultrasonic Milling Circular Tool Made Of NOMEX Cellular Materials

Because of their low density, excellent heat insulation and heat preservationfunctions, high specific strength and specific stiffness, NOMEX honeycomb materialsare paid much attention by aerospace field. However, special structure and specialfeatures of NOMEX honeycomb materials makes issues such as its appears torn,collapsed and the tool get deformed easily. For these problems, the ultrasonic cuttingtechnique into NOMEX honeycomb material processing. This article is based onultrasonic cutting NOMEX honeycomb material used in the milling tool for the study,developed a circular tool for the processing.This paper focuses on the structural design of circular tool. Starting from theprinciple of ultrasonic milling, The acoustic system of ultrasonic vibration millingwas designed, the finite element analysis is applied to study deformation、stress、modeof circular tool, providing the theory study and the design of product of circular withthe product data. First3D models based on the design dimension of Φ51mm circulartool are established by software of ANSYS; the software of ANSYS is mainly used toanalysis the deformation and stress of cutting function model under the action ofcutting force to study the rules of stress and deformation of circular tool; the vibrationdifferential equation of the circular tool is established based on the theory of elasticitymechanics and the software of ANSYS is used to finish their mode analysis, studyingthe relation of frequency and the shape of vibration and the analysis of dynamicperformance of circular tool. And the affection of the dimension of cutting modelhaving on the circular tool is researched. According to the theory of elasticitymechanics, the stress math model of the circular is set up and the affection of cuttingforce on circular tool is finished by the software of ANSYS.Based on the structure of Φ51mm circular tool, developed Φ25mm Φ102mmcircular tool. Both circular tool for modal analysis. Get to remove the maximumamount of Φ25mm circular tool, and can shorten the processing time.Finally, use laser displacement sensors designed to amplitude measurements ofdeveloped Φ51mm circular tool. And using a Φ51mm circular tool to cut NOMEXhoneycomb material for a large number of ultrasonic milling experiments.Experimental results show that: under the ultrasonic vibrations the maximum amplitude of the circular tool is24.5μm. Processing the honeycomb material, circulartool benefits, process effect is good, the processing efficiency is high, and the cuttingprocess is easy to be realized, almost no burr to meet the processing requirements ofthe honeycomb sandwich composite material.This study used ultrasonic machining work developed tool provides a hightheoretical significance and value. Honeycomb paper results can provide sometheoretical guidance for processing, so that the cellular level of processing to achievea new level.