Analysis of friction and cutting parameters when milling honeycomb composite structures

Zarrouk, Tarik; Salhi, Jamal‐Eddine; Nouari, Mohammed; Salhi, Mourad; Atlati, Samir; Salhi, Najim; Makich, Hamid

doi:10.1177/16878140211034841

Cited by 15 publications

(6 citation statements)

References 18 publications

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“…Indeed, the latter increases with the increase of the depth of cut. These trends can obviously be explained by the fact that at a greater depth of cut, a greater volume of material is machined, hence an increase in the cutting force can be immediately observed, [32,33]. According to the obtained results, we found a slight variation of the cutting forces with the increase in the tilt angle taken between 0° and 5°.…”

Section: Effect Of Cutting Depth On Cutting Forces and Cutter Morphologymentioning

confidence: 59%

Optimization of the milling process for aluminum honeycomb structures

Zarrouk

Nouari

Salhi

et al. 2022

Int J Adv Manuf Technol

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The milling of aluminum honeycomb structures represents today an important scientific and technical research topic for many industrial applications: aerospace, aeronautic, automotive, and naval. The difficulties encountered when milling this type of materials are linked to the small thickness of the walls constituting the honeycomb cells and the ductility of the material structure. The milling of cellular composite structures requires specific and rigorous tools. In the present work, a 3D numerical modeling of the milling process of aluminum honeycombs has been developed using Abaqus / Explicit software. The effect of milling parameters, such as the spindle speed, the tilt angle, and the depth of cut have been particularly investigated in terms of cutting forces, surface integritu and chip morphology. To properly analyze and optimize the cutting process, experimental validation was done through milling tests with different cutting conditions. The comparison between numerical simulations and experimental tests shows that the three-dimensional model correctly reproduces the milling of this type of structure.

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Section: Effect Of Cutting Depth On Cutting Forces and Cutter Morphologymentioning

confidence: 59%

Optimization of the milling process for aluminum honeycomb structures

Zarrouk

Nouari

Salhi

et al. 2022

Int J Adv Manuf Technol

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“…Jaafar et al. [ 22 ] and Tarik [ 27 ] have concluded similar results through simulation of the machining process and have shown that at higher feed rates, the cutting force increase while the chip size tends to be smaller. Similarly, in the case when DoC is increased, the accumulation of material results in increased shearing forces.…”

Section: Discussionmentioning

confidence: 76%

Enhancing Cutting Efficiency and Minimizing Forces for Nomex Honeycomb Core Using Grey Relational Analysis and Desirability Function Analysis

Habib,

Khan,

Munir

et al. 2023

Small Methods

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Nomex Honeycomb core is the foundational building block for manufacturing aerospace composite components. Its usage requires machining honeycomb in complex aerodynamic profiles where the quality of the core is governed by accuracy and precision of cut profiles. The assessment of accuracy and precision is directly related to forces induced in the cutting tool and cutting efficiency. These two parameters form the basis of a multi‐objective function that this paper aims to optimize for the milling operation. The parameter of depth of cut considered in this paper has not been analyzed in a multi‐objective optimization study of the Nomex Honeycomb core previously. A Taguchi‐based array of Design of Experiments followed by Analysis of Variance and correlation analysis is utilised. The results indicate that the most significant factor is the feed rate, with a percentage contribution of 72% for the cutting forces and depth of cut, with a percentage contribution of 85% in the case of cutting efficiency. The two parameters are optimized using Desirability Function Analysis and Grey Relational Analysis. The results are validated through experimental runs with an error within 5% of the statistical predictions, with the percentage improvement in cutting forces for optimum runs as compared to the worst experimental run at 47.8%. The percentage improvement in cutting efficiency likewise is 11%.

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“…As for contact conditions between the cutting tool and the specimen, 'Hard contact' enforced with a Lagrange multiplier representing the contact pressure in a mixed formulation was used to model the normal behavior, and Coulomb friction implemented with the penalty contact algorithm (relative motion in the absence of slip is equal to the friction force divided by the penalty stiffness) was established to model the tangential behavior. Due to discontinuous distribution and small thickness of the honeycomb walls, the contact area between the wall and the cutting tool is minimized so that a low friction coefficient between 0.1~0.25 [14,19,20] is fine for simulation.…”

Section: Honeycomb Cutting Modelmentioning

confidence: 99%

Study on the Cutting Damage Mechanism of Aramid Honeycomb Based on the Progressive Damage Model

et al. 2022

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A progressive damage model for aramid honeycomb cutting was proposed to reveal its cutting damage mechanism. It established the relationship between the mesoscale failure modes and the macroscale cutting damage types of the aramid honeycomb. The proposed model addressed the material assignment problem of impregnated honeycomb by developing a material calculation method that simulates the real manufacturing process of the aramid honeycomb. Cutting experiment of aramid honeycomb specimen was conducted concerning on the cutting forces response and cutting damages, which validated that the proposed method was effective for investigating the cutting process and mechanism for the aramid honeycomb. Predicted cutting mechanism results show that: (a) cutting process of the aramid honeycomb can be divided into three stages with four characteristic states—initial state, cut-in state, cut-out state and final state; (b) cell wall bending in the cutting direction relieves the cutting force, and strong plasticity of the aramid fiber makes it hard to break, which lead to uncut fiber and burr damages; (c) using sharp tip cutting tool to reduce cutting force and bonding both top and bottom of the honeycomb to make it stiffer are beneficial to obtain good cutting quality with less damages.

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Analysis of friction and cutting parameters when milling honeycomb composite structures

Cited by 15 publications

References 18 publications

Optimization of the milling process for aluminum honeycomb structures

Optimization of the milling process for aluminum honeycomb structures

Enhancing Cutting Efficiency and Minimizing Forces for Nomex Honeycomb Core Using Grey Relational Analysis and Desirability Function Analysis

Study on the Cutting Damage Mechanism of Aramid Honeycomb Based on the Progressive Damage Model

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