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Influence of cutting tool geometry when milling Nomex honeycomb structure

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Abstract

The use of Nomex honeycomb structures is essential for the aerospace and aeronautics industry because of their high out-of-plane strength and their advantageous weight/rigidity ratio. Nevertheless, milling these structures presents technical and scientific challenges, including premature wear of cutting tools and the quality of the machined surface. In general, the machining process relies on carrying out experimental tests. However, the high rotation speed of the cutting tool makes it difficult to monitor the cutting process correctly. Thus, it has become imperative to adopt reliable numerical models to collect instantaneous and accurate physical data. For this purpose, a 3D finite element numerical model was developed using the Abaqus/Explicit software, taking into account the real conditions of the experiment. An experimental validation was carried out by analyzing the premature wear of the cutting tool. After having validated the numerical model, an in-depth analysis was carried out to evaluate the influence of the number of teeth of the cutting tool on the optimization of the machining of the Nomex honeycomb structure. This analysis specifically focused on the cutting forces, the quality of the machined surface, and the accumulation of chips in front of the cutting tool. The obtained results clearly underline that low feed rates improve the integrity of the cutting tool, while a limited number of cutting tool teeth significantly improves cutting forces and the quality of the machined surface.

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Authors and Affiliations

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

    Tarik Zarrouk & Abdelkader Benbouaza

  2. Laboratoire LPTPME, Équipe Des Sciences Des Matériaux, Énergies Nouvelles Et Applications, Université Mohamed 1er, Faculté Des Sciences, 60000, Oujda, Morocco

    Tarik Zarrouk

  3. Laboratoire LEM3, UMR CNRS 7239, Institut Mines-Télécom (InSIC), Université de Lorraine, 27 Voie de L’Innovation, 88100, Saint-Dié, France

    Mohammed Nouari

  4. Laboratoire de Recherche de Génie Electrique Et Maintenance, Ecole Supérieure de Technologie, Université Mohammed 1er, 60000, Oujda, Morocco

    Abdelkader Benbouaza & Abdelilah Bouali

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  1. Tarik Zarrouk
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  2. Mohammed Nouari
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  3. Abdelkader Benbouaza
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  4. Abdelilah Bouali
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TZ performed analyzed and interpreted data and results. MN analyzed and interpreted data and was a major contributor to writing the manuscript. AB analyzed and interpreted data and results. AB was a major contributor to writing the manuscript. All authors read and approved the final manuscript.

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Correspondence to Tarik Zarrouk.

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Zarrouk, T., Nouari, M., Benbouaza, A. et al. Influence of cutting tool geometry when milling Nomex honeycomb structure. Int J Adv Manuf Technol 130, 649–663 (2024). https://doi.org/10.1007/s00170-023-12729-8

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