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Influence of the cutting tool geometry on milling aluminum honeycomb structures

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Abstract

The manufacture of aluminum honeycomb structures is a major concern for companies in the aerospace industry, due to its out-of-plane high strength and stiffness-to-weight ratio. However, the shaping of this type of structure represents a technical challenge for engineers and researchers in terms of premature wear of the cutting tool and the quality of the machined surface. Generally, machining studies are based on experimental tests. Nevertheless, the experimental procedure fails to follow the mechanism of chip formation due to high rotational speeds of the cutting tool. To this end, it is necessary to use robust and reliable numerical models to access instantaneous and much localized physical quantities. For this purpose, we have developed a 3D finite element model associated with real working conditions using the Abaqus/Explicit analysis software. Based on this model, an experimental validation was carried out by analyzing the appropriate behavior laws. Furthermore, the influence of the geometry of the cutting tool in terms of the number of teeth on the size of the chips, the cutting forces, and the quality of the generated surface was analyzed. The obtained results show that the integrity of the cutting tool can be optimized and the quality of the machined surface can be improved.

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Authors and Affiliations

  1. Laboratoire LPTPME, Équipe des Sciences des Matériaux, Énergies Nouvelles et Applications, Université, 60000, Oujda, Morocco

    Tarik Zarrouk & Jamal-Eddine Salhi

  2. CREHEIO (Centre de Recherche de l’Ecole des Hautes Etudes d’Ingénierie), 60000, Oujda, Morocco

    Tarik Zarrouk & Jamal-Eddine Salhi

  3. Université de Lorraine, CNRS, LEM3, IMT, GIP InSIC, F-88100, Saint Dié des Vosges, France

    Mohammed Nouari

  4. Faculté des Sciences, Univérsité Mohamed premier, 60000, Oujda, Morocco

    Merzouki Salhi

  5. Univérsité Claude Bernard, Lyon, France

    Jalal Kodad

Authors
  1. Tarik Zarrouk
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  2. Jamal-Eddine Salhi
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  3. Mohammed Nouari
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  4. Merzouki Salhi
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  5. Jalal Kodad
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Contributions

TZ performed analyzed and interpreted data and results. JES was a major contributor in writing the manuscript. MN analyzed and interpreted data and was a major contributor in writing the manuscript. MS analyzed and interpreted data and results. JK was a major contributor in writing the manuscript.

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Correspondence to Tarik Zarrouk.

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Zarrouk, T., Salhi, JE., Nouari, M. et al. Influence of the cutting tool geometry on milling aluminum honeycomb structures. Int J Adv Manuf Technol 126, 313–324 (2023). https://doi.org/10.1007/s00170-023-11144-3

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  • DOI: https://doi.org/10.1007/s00170-023-11144-3

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