A novel method of blade-inclined ultrasonic cutting Nomex honeycomb core with straight blade

2020 ◽  
pp. 1-34
Author(s):  
Yidan Wang ◽  
Renke Kang ◽  
Zhigang Dong ◽  
Xuanping Wang ◽  
Dehong Huo ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Honeycomb Core ◽  
Straight Blade ◽  
Machining Quality ◽  
Cutting Geometry ◽  
Novel Method ◽  
Nomex Honeycomb ◽  
Honeycomb Cores ◽  
Ultrasonic Cutting

Abstract Ultrasonic cutting with a straight blade is an advanced cutting method for Nomex honeycomb core. However, crushing has generally been observed on the machining surface of the honeycomb core in ultrasonic cutting (UC). In this paper, aiming at avoiding crushing, a new blade-inclined ultrasonic cutting (BIUC) method is proposed to decrease the geometric interference between the cutting tool and the honeycomb cores. The cutting geometry systems of UC and BIUC with a straight blade are systematically established to study the effect of cutting geometry on the machining quality. The crushing degrees caused by the major flank under different tool orientations in UC and BIUC are analyzed. The causes of crushing during the machining of the honeycomb core were revealed from aspects of machining quality, cutting force and geometric interference between the major flank and the material. Experiments on quantitive analysis of crushing and cutting forces verify that the BIUC method is able to avoid crushing by controlling the cutting angle. This paper provides a new method for solving the crushing problem in machining honeycomb core with the straight blade.

Research on Curved Surface Forming of Nomex Honeycomb Material Based on Ultrasonic NC Cutting

2012 ◽  
Vol 538-541 ◽  
pp. 1377-1381 ◽  
Author(s):  
Xiao Ping Hu ◽  
Sen Yan Chen ◽  
Zhi Chuang Zhang
Keyword(s):  
Composite Material ◽  
Cutting Tool ◽  
Milling Process ◽  
Curved Surface ◽  
Composite Processing ◽  
Cutting Method ◽  
Nomex Honeycomb ◽  
Honeycomb Material ◽  
Ultrasonic Cutting

This article introduced the Nomex honeycomb composite material, analyzed the insufficient of the traditional milling process in Nomex honeycomb composite processing, and proposed using the characteristics of ultrasonic cutting combined with NC technology to process the honeycomb composites. It analyzed the forming principle of the corresponding curved surface according to the special ultrasonic cutting tool and cutting method, and established a corresponding error.

Study on ultrasonic vibration–assisted cutting of Nomex honeycomb cores

2019 ◽  
Vol 104 (1-4) ◽  
pp. 979-992 ◽  
Author(s):  
Di Kang ◽  
Ping Zou ◽  
Hao Wu ◽  
Jingwei Duan ◽  
Wenjie Wang
Keyword(s):  
Ultrasonic Vibration ◽  
Nomex Honeycomb ◽  
Honeycomb Cores

A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

2007 ◽  
Vol 7 (3) ◽  
pp. 192-202 ◽  
Author(s):  
Jing Zhou ◽  
Derek Yip-Hoi ◽  
Xuemei Huang
Keyword(s):  
Analytical Solution ◽  
Critical Points ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Critical Component ◽  
Turning Process ◽  
Boolean Operations ◽  
Feature Based ◽  
Solid Modeler ◽  
Turning System

In order to optimize turning processes, cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler, and feature-based methodology for extracting TWEs generated during general turning. Although a pure solid modeler-based solution can be applied, it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This solution identifies features in the removal volumes, where the engagement conditions are not changing or changing predictably. This leads to significant reductions in the number of Boolean operations that are executed during the extraction of TWEs and associated parameters required for modeling a turning process. TWE extraction is a critical component of a virtual turning system currently under development.

Ballistic Impact Response of Foam-Filled Sandwich Composites

2001 ◽  
Author(s):  
Uday K. Vaidya ◽  
Biju Mathew ◽  
Chad A. Ulven ◽  
Brent Sinn ◽  
Marian Velazquez
Keyword(s):  
Cost Effective ◽  
Impact Response ◽  
Sandwich Composites ◽  
High Velocity Impact ◽  
Honeycomb Core ◽  
Velocity Impact ◽  
Foam Filling ◽  
Foam Filled ◽  
Honeycomb Cores ◽  
The Cost

Abstract Sandwich composites find increasing use as flexural load bearing lightweight sub-elements rail / ground transportation and marine bodies. In recent year, alternatives to traditional foam and honeycomb cores are being sought. One such development includes filling the cells of the honeycomb core with foam. The increased surface area allows stress forces to dissipate over a larger area than that offered by the honeycomb alone. This allows for use of lowering the cost of the honeycomb cells, and thereby making the design extremely cost-effective. In the present research, phenolic impregnated honeycomb / corrugated cells with polyurethane foam filling has been considered. The intermediate and high velocity impact response of these types of sandwich constructions has been studied. The applications for such cores would be in rail and ground transportation, where impacts in the form of flying debris are common.

Ultrasonic Cutting of Switchgrass and Miscanthus Stems

2018 ◽  
Vol 34 (2) ◽  
pp. 343-353
Author(s):  
A. Bulent Koc Koc ◽  
Bo Liu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Frequency ◽  
Cutting Speed ◽  
Particle Size Reduction ◽  
Element Analysis ◽  
Cutting Energy ◽  
High Frequency Vibrations ◽  
Ultrasound Assisted ◽  
Ultrasonic Cutting

Abstract. Ultrasound-assisted cutting has been used to cut materials with high precision, improved quality and reduced cutting forces. The research objective was to investigate the effects of high-frequency vibrations on the cutting force and cutting energy of switchgrass and miscanthus stems. Laboratory experiments were conducted on individual biomass stems at cutting speeds between 3 and 400 mm/s. An experimental cutting system with an ultrasound generator, an ultrasonic blade, a load cell, and a data acquisition system was developed. The custom designed blade was 5-cm wide and vibrated at 19.551 kHz with 2.8 µm tip vibration amplitude. There were significant measured differences in the cutting forces and cutting energies between conventional cutting and ultrasonic cutting of switchgrass and miscanthus stems (p < 0.05). These results suggest that the use of high-frequency vibrations reduce cutting force and cutting energy of both switchgrass and miscanthus stems. Ultrasound-assisted cutting reduced the cutting energy of switchgrass by 66.85% at 100 mm/s and miscanthus by 80.58% at 30 mm/s. However, ultrasonic cutting did not have a significant effect on the cutting force and cutting energy when the cutting speed was equal to or greater than the blade tip vibration speed. The results of this research should be useful for adapting the ultrasonic technology in biomass harvesting, particle size reduction, and processing equipment. Keywords: Biomass, Blades, Energy, Finite element analysis, Miscanthus, Switchgrass, Ultrasonics.

Numerical Analysis and Mechanical Properties of Nomex™ Honeycomb Core

2017 ◽  
Author(s):  
Yue Liu ◽  
Weicheng Gao ◽  
Wei Liu ◽  
Zhou Hua
Keyword(s):  
Compressive Strength ◽  
Cell Walls ◽  
Mechanical Response ◽  
Compressive Loading ◽  
Fe Model ◽  
Honeycomb Core ◽  
Practical Applications ◽  
Honeycomb Sandwich ◽  
Nomex Honeycomb ◽  
Strength And Stiffness

This paper presents an investigation on the mechanical response of the Nomex honeycomb core subjected to flatwise compressive loading. Thin plate elastic in-plane compressive buckling theory is used to analyze the Nomex honeycomb core cell wall. A mesoscopic finite element (FE) model of honeycomb sandwich structure with the Nomex honeycomb cell walls is established by employing ABAQUS/Explicit shell elements. The compressive strength and compressive stiffness of Nomex honeycomb core with different heights and thickness of cell walls, i.e. double cell walls and single cell walls, are analyzed numerically using the FE model. Flatwise compressive tests are also carried out on bare honeycomb cores to validate the numerical method. The results suggest that the compressive strength and compression stiffness are related to the geometric dimensions of the honeycomb core. The Nomex honeycomb core with a height of 6 mm has a higher strength than that of 8 mm. In addition, the honeycomb core with lower height possesses stronger anti-instability ability, including the compressive strength and stiffness. The proposed mesoscopic model can effectively simulate the crushing process of Nomex honeycomb core and accurately predict the strength and stiffness of honeycomb sandwich panels. Our work is instructive to the practical applications in engineering.

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