Research on Design and Processing Characteristics of Disc Cutter in Ultrasonic Vibration Cutting Nomex Honeycomb Composites
SHANG Wenjun 1 , FENG Pingfa 1, 2 , ZHA Huiting 1 , XU Jie 1, 3 , YAN Jianhui 1 , LIU Shijie 1 , FENG Feng 1
1. Tsinghua Shenzhen International Graduate School, Shenzhen 518055, China;
2. Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;
3. Hunan Institute of Engineering, Xiangtan 411100, China
Abstract：The influence of the outside diameter, wedge angle and thickness of disc cutter on the mode and resonant frequency of ultrasonic machining system was studied by finite element simulation technology. The Nomex honeycomb composites experimental platform was built. A comparative experiment between conventional machining and ultrasonic assisted machining was carried out. Taking cutting force and surface quality as evaluation indexes, the improvement effect of ultrasonic vibration on Nomex honeycomb composites under different processing parameters was analyzed. The research results show that the resonant frequency of the system decreases with the increase of disc cutter diameter, increases with the increase of thickness, and decreases with the increase of wedge angle. The influence of the cutter diameter and thickness is more remarkable. The system frequency can be designed by adjusting the outside diameter and thickness of the tool. The size of wedge angle affect the sharpness and intensity of tools, the proper wedge angle should be choosed. The average cutting force in ultrasonic machining is 34.9% and 50.5% lower than that in conventional machining in cutting width direction and feed direction, respectively. The machined surface of composites in ultrasonic assisted machining is smoother, with fewer and shorter burrs.
2021, 
