Simulation and experimental study of ultrasonic cutting for aluminum honeycomb by disc cutter

Sun, Jiansong; Dong, Zhigang; Wang, Xuanping; Wang, Yidan; Qin, Yan; Kang, Ren Ke

doi:10.1016/j.ultras.2020.106102

Cited by 52 publications

(14 citation statements)

References 20 publications

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“…The results of the experiments are presented in the article [16]. The analysis of a 3D-FE model of the aluminum honeycomb ultrasonic cutting with a disc blade applying commercial software ABAQUS are provided.…”

Section: Related Workmentioning

confidence: 99%

Method for the Optimal Positioning of the Cutter at the Honeycomb Block Cutting Applying Computer Vision

2021

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The problem of optimal cutting of honeycomb blocks is considered in the article. The urgency of using irregular shapes application cutting from honeycomb blocks made of modern composite materials is substantiated. The problem is to obtain a cut of a given shape from honeycomb blocks. The optimal cutting plane of the single cell face of a honeycomb block is found on the basis of calculations for the stability and stretching force in adjacent faces applying a finite element method. The problem of obtaining faces and nodal points of a honeycomb block when calculating the coordinates of the optimal cut points of a real honeycomb block using machine vision methods. The most suitable algorithms, a part of the OpenCV library, are considered. The authors decided to develop their own algorithm for recognizing an irregular cellular structure since the existed algorithms did not solve the stated problem. As opposed to existing algorithms, the proposed one finds all the nodal points and faces even on the deformed sections of the honeycomb block avoiding false faces. The method helps to find coordinates of all nodal points and determine the connection of adjacent points with a face. As a result, real faces, not perfect geometrically, are replaced by line segments. The test result proves its correctness and practical applicability. The proposed method solves an optimal cutting problem of aluminum honeycomb block. It should be noted that the proposed method is customizable and can be applied to any honeycomb or cellular panels.INDEX TERMS Image recognition, composite materials, cutting tools, machine vision.

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Section: Related Workmentioning

confidence: 99%

Method for the Optimal Positioning of the Cutter at the Honeycomb Block Cutting Applying Computer Vision

2021

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“…Recently, Sun et al [35] have been developed with ABAQUS software a 3D FE model of ultrasonic cutting for aluminum honeycomb by a disc cutter. In the thin cell walls, the constitutive behavior of workpiece material has been modelled by the Johnson Cook law.…”

Section: Introductionmentioning

confidence: 99%

3D numerical modeling and experimental validation of machining Nomex® honeycomb materials

Jaafar

Nouari

Makich

et al. 2021

Int J Adv Manuf Technol

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HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. L'archive ouverte pluridisciplinaire HAL, est destinée au dépôt et à la diffusion de documents scientifiques de niveau recherche, publiés ou non, émanant des établissements d'enseignement et de recherche français ou étrangers, des laboratoires publics ou privés.

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“…Therefore, a mechanical horn is required between the transducer and the cutting tool to enhance the amplitude of vibration. Reasonably good machining quality and reduction of forces have been achieved through ultrasonic machining technology [5,[7][8][9].…”

Section: Introductionmentioning

confidence: 99%

Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

Mughal

Qureshi

Qaiser

et al. 2021

Preprint

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Ultrasonic horn plays vital role in achieving vibration amplitude suitable for efficient machining of advanced composites. Due to very high operating frequency of at least of ultrasonic machining system, horn may be subjected to high stresses leading to failure. Mechanical horn is designed to get optimum vibration amplification while keeping stresses in acceptable limits. In this research, state of the art ultrasonic horns were designed with same length and diameters at the transducer side and tool ends under similar operating conditions. All standard and hybrid ultrasonic horns, including some new designs, suitable for machining applications were evaluated through finite element analysis. Modal analysis was performed for computing axial modal frequencies, whereas harmonic analysis was carried out to determine vibration amplitude, stresses and factor of safety. The performance of state of the art ultrasonic horn designs were later compared in terms of vibration amplification, stresses and operating life. The axial modal frequency and amplitude of vibration achieved by barrel, cylindrical-double conical and hollow exponential horns were observed to be greater as compared to the step horn, however the former were prone to greater stress concentrations and low operating life. Reasonably higher vibration amplification, factor of safety and low stresses were achieved by Bezier, cylindrical-catenoidal, cylindrical-Bezier, step-conical, step-catenoidal, step-Bezier, double conical, multistep and multistep-conical horn designs. Remarkably, circular hollow exponential and multistep-conical ultrasonic horns were observed to achieve vibration amplification, factor of safety and operating life higher than that of commercially available step horn.

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Simulation and experimental study of ultrasonic cutting for aluminum honeycomb by disc cutter

Cited by 52 publications

References 20 publications

Method for the Optimal Positioning of the Cutter at the Honeycomb Block Cutting Applying Computer Vision

Method for the Optimal Positioning of the Cutter at the Honeycomb Block Cutting Applying Computer Vision

3D numerical modeling and experimental validation of machining Nomex® honeycomb materials

Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

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