Characterization Of Ultrasonic Vibration Milling Force Of Aramid Honeycomb Material

Since the introduction of aramid honeycomb materials,they have been making a splash in the aviation and aerospace sectors with advantages that traditional materials do not have.Especially in recent years,honeycomb materials have developed more rapidly and their application areas have been further expanded.However,due to its orthogonal and anisotropic mechanical properties,traditional processing methods tend to cause honeycomb core deformation,poor processing quality and low yield rate.Ultrasonic vibration-assisted milling is a new processing method combining ultrasonic vibration and traditional milling methods,which has the advantages of low dynamic milling force,high surface quality and high surface quality,and is particularly suitable for the processing of difficult materials.In order to explore the milling force characteristics of ultrasonic vibration-assisted machining of aramid honeycomb materials,this paper presents a theoretical analysis and experimental study of ultrasonic vibration-assisted machining of aramid honeycomb materials,relying on an ultrasonic vibration-assisted milling test platform designed and built by the group to carry out milling force analysis.The main research elements are as follows.In this paper,an ontological model for the selected honeycomb material is derived to provide a theoretical basis for setting the properties of the honeycomb material in the subsequent simulation model.The kinematic analysis of ultrasonic vibration-assisted milling of aramid honeycomb materials with straight and disc cutters was carried out to investigate the cutting edge trajectories and derive the milling force expressions.Theoretical calculations show that ultrasonic vibration can effectively reduce the milling forces during the machining of aramid honeycomb materials.Based on the requirements of the CNC machine tool and the ultrasonic vibration generation system,the structural design and simulation verification of two types of ultrasonic machining tools,the straight-edge tool and the disc tool,were carried out,and the milling force test platform was built.Based on an in-depth analysis of the intrinsic structure model of the aramid honeycomb material and the characteristics of the milling process,a combination of theoretical analysis and experimental research was used to simulate and test the two machining methods of ultrasonic vibration-assisted milling and general milling on the aramid honeycomb material.Relying on the built test platform,milling machining tests were carried out.A three-factor,four-level orthogonal test with a disc cutter was designed to investigate the extent to which feed rate,machine spindle speed and milling depth affect milling forces under normal and ultrasonic vibration-assisted milling conditions,and a self-programmed Lab VIEW programme was used for data acquisition.A finite element simulation of the machining process with and without ultrasonic vibration-assisted milling of aramid honeycomb material was carried out with N16 sets of experimental parameters.By comparing and analysing the experimental and simulation data,it can be seen that after the application of ultrasonic vibration,the feed rate is the main factor in the three-way component force,and the weight of the milling depth and machine spindle speed increases.