Study On Cutting Force In Nomex Honeycomb Composites' Ultrasonic Cutting By Straight Blade Knife

Having good electric characteristics and mechanics characteristics, including low density, high longitudinal stiffness, good at thermal isolation and electrical insulation, high strength rate and specific stiffness, Nomex honeycomb composites sandwich structure is widely used in the areas of aerospace aviation, automobile production, weapon manufacture and some other manufacturing industries. Because of its low longitudinal stiffness, it is a typical difficult-to-process flexible material. Some quality problems offen appear in Nomex honeycomb forming parts of traditional milling such as tackles, cracking, burr, etc., which can't be used in practical manufacturing.In recent years, ultrasonic cutting becomes a new important technique used in the area of composite cutting. Because of its high efficiency, less damage, chipless and dust-free machining which can solve the problems in traditional machining, ultrasonic cutting is widely used in aerospace manufacturing industry. Some foreign enterprises have put the USM technique into Nomex complex surface machining and get the special equipment. Domestic aviation manufacturing enterprises have introduced ultrasonic cutting machines and equipment, but domestic researches on ultrasonic cutting processing mechanism of composite are just on the foundation Stage. Studying the ultrasonic cutting mechanism of Nomex honeycomb and optimizing the machining parameters of cutting different types of Nomex honeycomb, will do helps to improve the machining efficiency and quality, and popularize the its application in the industrial fields.In this paper, based on the manufacturing Procedure of straight blade knife cutting Nomex honeycomb composite, studied the ultrasonic cutting mechanism and technological parameter selection. The main research contents are as follows:(1) Built the ultrasonic vibration cutting processing system, tested the vibration performance.(2) Based on the changing procedure of material's internal dynamic stress, studied the effect on cutting procedure caused by ultrasonic vibration, analysed the failure mode under the ultrasonic effection; judged the direction of ultrasonic vibration effect, studied the effect rules of every technological parameter's on cutting force.(3) Built the ultrasonic vibration cutting experiment platform, carried out the ultrasonic vibration cutting experiment, proved the effect rules of ultrasonic vibration; analysed the effect rules of cutting force under different technological parameters, observed the cutting quality of the processed materials. It shows that the experiment results share the same law with theoretical analysis, and using appropriate technological parameters can reduce the cutting force, increase the quality of cutting surface and material structure.