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Formation mechanism of tearing defects in machining Nomex honeycomb core

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Abstract

Nomex honeycomb core has been widely applied in aerospace industries due to its superior strength and rigidity. However, the machining defects of honeycomb core can deteriorate the bonding strength between honeycomb core and connective face sheet. This paper investigates the tearing defects formatted in milling process of Nomex honeycomb core. Firstly, a cutting force model is proposed to predict the milling forces under various tool entrance angles. Then, finite element simulation for machining honeycomb wall is conducted to reveal the formation mechanism of tearing defects. The accuracy of the model is verified by a group of experiments under different entrance angles and the relative error is below 25% in 1-direction and 20% in 2-direction. It is found that the formation of tearing defects is closely related to the deformation of honeycomb wall and the component of cutting force in direction parallel to wall. The tool entrance angle can be thus optimized based on the reduction of tearing defects. The optimized entrance angle of double wall is among 40° and 70°.

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The data and material in this paper are available from the corresponding author on reasonable request.

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Funding

This work was supported by the National Key Research and Development Program of China (grant numbers 2019YFB2005401), Taishan Scholar Foundation, and Shandong Provincial Natural Science Foundation of China (ZR2019MEE073 and 2019JMRH0307).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Jiaming Jiang & Zhanqiang Liu

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE/Key National Demonstration Center for Experimental Mechanical Engineering Education, Jinan, 250061, Shandong, China

    Jiaming Jiang & Zhanqiang Liu

Authors
  1. Jiaming Jiang
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  2. Zhanqiang Liu
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Contributions

Zhanqiang Liu and Jiaming Jiang conceived of the presented idea; Jiaming Jiang developed the theory and performed the computations; Jiaming Jiang and Bing Wang discussed the results and commented on the manuscript; all authors provided feedback and helped shape the research, analysis, and manuscript.

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Correspondence to Zhanqiang Liu.

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Jiang, J., Liu, Z. Formation mechanism of tearing defects in machining Nomex honeycomb core. Int J Adv Manuf Technol 112, 3167–3176 (2021). https://doi.org/10.1007/s00170-021-06603-8

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