A honeycomb structure is widely used in sandwich structure components in aeronautics and astronautics; however, machining is required to reveal some of its features. In honeycomb structures, deficiencies, such as burrs, edge subsiding, and cracking, can easily appear, owing to poor specific stiffness in the radial direction. Some effective fixation methods based on a filling principle have been applied by researchers, including approaches based on wax, polyethylene glycol, iron powder, and (especially) ice. However, few studies have addressed the optimization of the cutting parameters. This study focused on optimizing the cutting parameters to obtain a better surface roughness (calculated as a roughness average or R a ) and surface morphology in the machining of an aluminum alloy honeycomb by an ice fixation method. A Taguchi method and an analysis of variance were used to analyze the effects and contributions of spindle speed, cutting depth, and feed rate. The optimal cutting parameters were determined using the signal-to-noise ratio combined with the surface morphology. An F-value and P-value were calculated for the value of the R a , according to a "smaller is better" model. Additionally, the optimum cutting parameters for machining the aluminum honeycomb by ice fixation were found at different levels. The results of this study showed that the optimal parameters were a feed rate of 50 mm/min, cutting depth of 1.2 mm, and spindle speed of 4000 r/min. Feed rate was the most significant factor for minimizing R a and improving the surface morphology, followed by spindle speed. The cutting depth had little effect on R a and surface morphology. After optimization, the value of R a could reach 0.218 μm, and no surface morphology deterioration was observed in the verified experiment. Thus, this research proposes optimal parameters based on ice fixation for improving the surface quality.

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C-C composite is a kind of typical difficult-to-machine materials due to its high hardness, high strength, and obvious anisotropy features. But, water-based or oil-based coolant cannot be used during its machining process. As a result, the machining defects, including burrs, orifice ripping, and interlayer delamination, are always unavoidable. In this article, taking the liquid nitrogen as coolant, C-C composite cryogenic drilling is researched experimentally. Taking the way of LN2 external spray cooling, a series of cryogenic drilling experiments were designed. Comparing with dry drilling, the thrust force was reduced, the machining defects were significantly inhibited, and a better roundness of holes was achieved in cryogenic drilling. It indicates that cryogenic condition has a positive effect on improving the C-C composite drilling quality.