采用半圆弧刀具超声插切Nomex蜂窝芯的新方法

Nomex蜂窝芯材料具有各向异性、弱刚度的特点,是一种典型的难加工材料。为解决传统插切刀具加工Nomex蜂窝芯时存在的排屑困难、切屑侧的压溃面积大等问题,提出一种采用半圆弧刀具超声插切Nomex蜂窝芯的加工方法。设计了一种新型半圆弧形插切刀具,分析了超声作用下半圆弧形插切刀具的运动规律,揭示了超声振动的引入使切削过程由连续切削变为断续切削的机理。开展了半圆弧刀具超声插切Nomex蜂窝芯的试验,分析了振幅与进给速度对切削力与切削质量的影响规律。试验结果表明,半圆弧刀具超声插切Nomex蜂窝芯可获得良好的加工效果,超声振动的引入可有效降低插切切削力,提高切削表面质量。研究的半圆弧刀具超声插切技术为蜂窝芯零件轮廓边界的高质量加工提供了新的方法。

New Method of Ultrasonic Slotting Nomex Honeycomb Core With Semi-Circle Arc Tool

Nomex honeycomb core is a kind of typical difficult-to-cut materials because of the characteristics of anisotropy and weak-stiffness.Aimed at solving the problem of chip removal and serious crushing on the chip side during the processing of Nomex honeycomb core with traditional trepanning tool,a new method of ultrasonic slotting Nomex honeycomb core with semi-circle arc tool was proposed.A new semi-circular arc tool was designed,the kinematic law of the semi-circular arc tool with ultrasonic vibration was analyzed,and the transition mechanism of continuous cutting into intermittent cutting was explained theoretically in ultrasonic cutting.On these basis,ultrasonic slotting tests of Nomex honeycomb core were carried out,and the influences of the amplitude and feed rate on cutting force and cutting quality were studied.The test results showed that satisfied processing results could be obtained by the ultrasonic slotting of Nomex honeycomb core with semi-circle arc tool,and the introduction of ultrasonic could effectively reduce the cutting force and improve the surface quality.The ultrasonic slotting technology of semi-circular arc tool provided a new method for highquality cutting process of the edge contour of the honeycomb core.