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Cell wall fracture mechanism in ultrasonic-assisted cutting of honeycomb materials

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Abstract

Revealing the ultrasonic cutting mechanism of honeycomb composite is important for determining the acoustic parameters of the ultrasonic system and selecting the parameters of the cutting process. Understanding more details of the stress on the cell wall from ultrasonic vibrating tool and the conditions for cell wall breakage is essential to study the machining mechanism. According to the evolution of contact state between the straight edge cutter and the honeycomb cell wall in a cycle, the cutting force acting on the cell wall is divided into three stages: transverse cutting load action, longitudinal cutting load action, and no cutting load action. The cell wall deflection and stress equations under transverse cutting load were established by applying elastic thin plate small deflection theory. The deformation and fracture characteristics of the honeycomb cell wall were analyzed by combining the analytical and the finite element model. The results showed that the ultrasonic vibration of the cutter greatly improved the stiffening effect of the cell wall and its fracture was caused by the deflection under the transverse cutting load, which exceeded the maximum allowable deformation after local stiffening. In addition, with only longitudinal cutting load, it was difficult to break the critical buckling state that leads to cell wall fracture.

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Funding

The National Natural Science Foundation of China (No.51975173), Zhejiang Province Public Welfare Technology Application Research Project (No. LGG21E050010),

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Authors and Affiliations

  1. School of Mechanical Engineering, Hangzhou Dianzi University, Hangzhou, 310018, China

    Baohua Yu, Sufang Yao, Xin Wu & Xiaoping Hu

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  1. Baohua Yu
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  2. Sufang Yao
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  3. Xin Wu
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  4. Xiaoping Hu
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Contributions

Baohua Yu comprehensively analyzed the simulation and data results, drew conclusions and wrote part of the paper. Sufang Yao deduced the theoretical equation, did experiments, and wrote part of the paper. Xin Wu did simulation experiments. Xiaoping Hu designed and studied the technical route.

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Correspondence to Xiaoping Hu.

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Yu, B., Yao, S., Wu, X. et al. Cell wall fracture mechanism in ultrasonic-assisted cutting of honeycomb materials. Int J Adv Manuf Technol 121, 5067–5078 (2022). https://doi.org/10.1007/s00170-022-09671-6

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  • DOI: https://doi.org/10.1007/s00170-022-09671-6

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