Title: 3D FE cutting simulations of Nomex honeycomb composites in rotary ultrasonic machining process

Authors: Shahzad Ahmad; Jianfu Zhang; Jianjian Wang; Pingfa Feng; Xiangyu Zhang

Addresses: Beijing Key Laboratory of Precision/ Ultra-Precision Manufacturing Equipment and Control, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China; Department of Mechanical Engineering, Muhammad Nawaz Sharif University of Engineering and Technology (MNS UET), Multan 60600, Pakistan ' Beijing Key Laboratory of Precision/ Ultra-Precision Manufacturing Equipment and Control, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China; State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China ' Beijing Key Laboratory of Precision/ Ultra-Precision Manufacturing Equipment and Control, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China ' Beijing Key Laboratory of Precision/ Ultra-Precision Manufacturing Equipment and Control, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China; State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China ' Beijing Key Laboratory of Precision/ Ultra-Precision Manufacturing Equipment and Control, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

Abstract: In this research a 3D FE rotary ultrasonic cutting simulation model of NHCs core material was developed based on Hashin failure criterion and novel ultrasonic circular saw blade cutter system. Further, 3D FE cutting simulation model was validated by performing RUM experiments on ultrasonic machine tool and explored. Cutting force exhibits inverse relation with vibration amplitude and spindle speed of ultrasonic circular saw blade tool, whereas it shows direct relation with feed rate. Finally, an optimised set of processing parameters was obtained by performing series of cutting simulations and verified by experimental work with a novel ultrasonic circular saw blade cutting tool at resonant frequency of 22,050 Hz, spindle speed 3,000 rpm, feed rate 500 mm/min, cutting width 8 mm, cutting depth 2 mm, and vibration amplitude 25 µm. Moreover, this study provides systematic guideline for RUM process optimisation and improvements of surface quality.

Keywords: 3D FE modelling; cutting simulations; Nomex honeycomb composites; NHCs; rotary ultrasonic machining; RUM; processing parameters optimisation; chips formation.

DOI: 10.1504/IJMMM.2024.137424

International Journal of Machining and Machinability of Materials, 2024 Vol.26 No.1, pp.58 - 84

Received: 26 Feb 2023
Accepted: 29 Jun 2023
Published online: 18 Mar 2024 *