Research On Ultrasonic Vibration Cutting Technology Of Nomex Honeycomb Core Composite Material

Nomex honeycomb core composites are widely used in modern aviation,aerospace and other fields for their excellent characteristics such as high specific strength and specific stiffness,light weight,self-extinguishing and insulating properties,high temperature resistance,chemical stability and adaptability.In order to satisfy the needs of assembly and connection,NC machining is necessary for Nomex honeycomb core composites.But their processing performance gets bad with the special structure which is anisotropic,and the conventional processing methods are difficult to process.It will take bad quality and performance with the different defects in traditional processing.In addition,the dust during process will take serious environmental pollution.So it has great significance to investigate efficient and precise machining process in its application in all fields.Ultrasonic vibration cutting is widely used in foreign countries for it can effectively solve the problems existing in traditional processing in recent years.However,the domestic research on this technology is less is less and the process tools,parameters,and NC program is decided by the existing process experience for lacking of relevant technology.In order to solve these problem,ultrasonic vibration cutting technology such as cutting mechanism,cutting parameters,programming methods,etc.of Nomex honeycomb core composites was carried out to improve the efficiency and quality of Nomex honeycomb core composites in this paper.The main research contents of this article are as follows:(1)The tools and holding method in machine Nomex honeycomb core composites were investigated.The holding method is based on the characteristics and shape of Nomex honeycomb core composite in the vacuum absorption platform of machine tool.The two kinds machining ways with Dagger Tool and Disk Tool were investigated.(2)Modeling of ultrasonic vibration cutting force was investigated.Through the analysis of the stress and strain of the Nomex honeycomb core composites in cutting region,the influence of the ultrasonic vibration on the deformation was studied.Then cutting process of the Dagger Tool was analyzed theoretically,and the theoretical model of the cutting force is established,and experimental verification is carried out.The finite element simulation model based on ABAQUS,in rotary vibration cutting Nomex honeycomb core composites with Disk Tool was established and verified by experiments.(3)The optimization of ultrasonic vibration cutting process parameters for Nomex honeycomb core composites was studied.Based on the theoretical model of the cutting force of the Dagger Tool,the influence of the process parameters on cutting force in the ultrasonic cutting process was analyzed by MATLAB software.With the simulation data of the Disk Tool,the theoretical cutting force prediction model in the rotary vibration cutting was established by the central compound response surface method.The effect on cutting force of cutting parameters was studied and the parameters were optimized by genetic algorithm.(4)NC programming technology in ultrasonic vibration cutting of Nomex honeycomb core composites was studied.The equivalent cutting tool is set up based on the tool structure.With the section method and the analysis of the characteristics of the parts of honeycomb core composites,the formation of the trajectory of the ultrasonic vibration cutting and the control of the tool position were studied.The difficult problems of the NC programming and post processing technology in ultrasonic vibration cutting were studied under the actual working conditions.