Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutter
Nomex® honeycomb composites (NHCs) with circular arc features are a challenging issue in the machining of aviation curved structural components. Compared to linear feature machining, arc feature machining involves six-axis coordinated motion, introducing additional variables. Directly referencing th...
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| Format: | Article |
| Language: | English |
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Elsevier
2024-01-01
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| Series: | Engineering Science and Technology, an International Journal |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2215098623002793 |
| _version_ | 1797356057238962176 |
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| author | Xinman Yuan Chuanrong Fan Jie Xu Wenjun Cao Wenchang Zhou Enlai Jiang Yuan Ma Chao Xu Pingfa Feng Feng Feng |
| author_facet | Xinman Yuan Chuanrong Fan Jie Xu Wenjun Cao Wenchang Zhou Enlai Jiang Yuan Ma Chao Xu Pingfa Feng Feng Feng |
| author_sort | Xinman Yuan |
| collection | DOAJ |
| description | Nomex® honeycomb composites (NHCs) with circular arc features are a challenging issue in the machining of aviation curved structural components. Compared to linear feature machining, arc feature machining involves six-axis coordinated motion, introducing additional variables. Directly referencing the linear feature machining process will lead to the deterioration of contour accuracy and surface quality in arc-trajectory machining (ATM). To further explore the influence of process variables on ATM, this study developed an error model for straight blade tool (SBT) ATM and investigated the influence of cutting-edge lead angles (γ) on contour accuracy and surface quality. A vertical cutting process was proposed, and experiments proved it provided the optimal machining quality (the defect rate of core cells was only 3.93 %) compared to forward and backward inclination cutting (7.23 %∼34.3 % and 9.71 %∼17.36 %, respectively). Additionally, it was revealed that the main reason for the deterioration of surface quality on ATM was the excessive angle between the cutting edge direction and the feed direction. Based on the results above, the influence and optimization of cutting-edge lead angles were revealed, and the advantage of vertical cutting process for machining NHCs with arc-trajectory was demonstrated. This research provides a feasible method for the machining of NHCs with arc-trajectory using SBT. |
| first_indexed | 2024-03-08T14:21:04Z |
| format | Article |
| id | doaj.art-58a66c08d56f42f0991b56436cf8f076 |
| institution | Directory Open Access Journal |
| issn | 2215-0986 |
| language | English |
| last_indexed | 2024-03-08T14:21:04Z |
| publishDate | 2024-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Engineering Science and Technology, an International Journal |
| spelling | doaj.art-58a66c08d56f42f0991b56436cf8f0762024-01-14T05:38:44ZengElsevierEngineering Science and Technology, an International Journal2215-09862024-01-0149101601Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutterXinman Yuan0Chuanrong Fan1Jie Xu2Wenjun Cao3Wenchang Zhou4Enlai Jiang5Yuan Ma6Chao Xu7Pingfa Feng8Feng Feng9AVIC Chengdu Aircraft Industrial (Group) Co., Ltd, Chengdu 610073, ChinaDivision of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, ChinaDivision of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, ChinaAVIC Chengdu Aircraft Industrial (Group) Co., Ltd, Chengdu 610073, ChinaAVIC Chengdu Aircraft Industrial (Group) Co., Ltd, Chengdu 610073, China; Corresponding authors.Division of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, China; Xiamen Golden Egret Special Alloy Co Ltd, Xiamen 361006, ChinaDivision of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, China; Shenzhen Tsingding Technology Co. Ltd., Shenzhen 518133, ChinaDivision of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, China; Shenzhen Tsingding Technology Co. Ltd., Shenzhen 518133, ChinaDivision of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, ChinaDivision of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen 518055, China; Corresponding authors.Nomex® honeycomb composites (NHCs) with circular arc features are a challenging issue in the machining of aviation curved structural components. Compared to linear feature machining, arc feature machining involves six-axis coordinated motion, introducing additional variables. Directly referencing the linear feature machining process will lead to the deterioration of contour accuracy and surface quality in arc-trajectory machining (ATM). To further explore the influence of process variables on ATM, this study developed an error model for straight blade tool (SBT) ATM and investigated the influence of cutting-edge lead angles (γ) on contour accuracy and surface quality. A vertical cutting process was proposed, and experiments proved it provided the optimal machining quality (the defect rate of core cells was only 3.93 %) compared to forward and backward inclination cutting (7.23 %∼34.3 % and 9.71 %∼17.36 %, respectively). Additionally, it was revealed that the main reason for the deterioration of surface quality on ATM was the excessive angle between the cutting edge direction and the feed direction. Based on the results above, the influence and optimization of cutting-edge lead angles were revealed, and the advantage of vertical cutting process for machining NHCs with arc-trajectory was demonstrated. This research provides a feasible method for the machining of NHCs with arc-trajectory using SBT.http://www.sciencedirect.com/science/article/pii/S2215098623002793Nomex® Honeycomb CompositesStraight blade toolArc-trajectory machiningUltrasonic cuttingMachining qualityCutting geometry |
| spellingShingle | Xinman Yuan Chuanrong Fan Jie Xu Wenjun Cao Wenchang Zhou Enlai Jiang Yuan Ma Chao Xu Pingfa Feng Feng Feng Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutter Engineering Science and Technology, an International Journal Nomex® Honeycomb Composites Straight blade tool Arc-trajectory machining Ultrasonic cutting Machining quality Cutting geometry |
| title | Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutter |
| title_full | Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutter |
| title_fullStr | Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutter |
| title_full_unstemmed | Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutter |
| title_short | Dominating influence of cutting-edge lead angles on arc-trajectory machining of Nomex® honeycomb composites by using a straight blade cutter |
| title_sort | dominating influence of cutting edge lead angles on arc trajectory machining of nomex r honeycomb composites by using a straight blade cutter |
| topic | Nomex® Honeycomb Composites Straight blade tool Arc-trajectory machining Ultrasonic cutting Machining quality Cutting geometry |
| url | http://www.sciencedirect.com/science/article/pii/S2215098623002793 |
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