Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure
Abstract
:1. Introduction
2. Finite Element Model
2.1. Material Parameters
2.2. Law of Behavior Applied
2.3. Chip Separation Criterion
2.4. Finite Element Modeling
2.5. Components of the Cutting Force
3. Results and Discussion
3.1. Mesh Size Study
3.2. Influence of Cutting Width on Cutting Force Components
3.3. Impact of Vibration Amplitude on Machined Surface
3.4. Analysis of the Distribution of Stresses and Displacements in the Cutting Zone
3.5. The Influence of Vibration Amplitude on the Size of the Chips Generated
4. Conclusions
- The study of the impact of the cutting width on the components of the cutting force is carried out, finding a significant increase in these components with increasing cutting width, both in simulations and in experiments. Our results suggest that the use of ultrasonic vibrations helps to mitigate the negative effects of the Fx and Fy components in both directions. Furthermore, a significant agreement between the results of the numerical model and the experimental data was observed.
- The amplitude of the ultrasonic vibration directly impacts the chip size, leading to a reduction in this one with increasing vibration amplitude.
- The amplitude of the vibration influences the surface quality, leading to an improvement of the latter when the amplitude of the vibrations is increased.
- Applying ultrasonic vibration to the cutting tool induces additional stress in the cutting area of the honeycomb cell wall, accelerating material deterioration while reducing cell wall deformation, facilitating a more efficient milling of the Nomex honeycomb core.
- By continuing this research, it is planned to develop the numerical model by taking into account other parameters in order to detect the burrs that form on the thin walls during the machining process.
- In the industrial context, the optimization of manufacturing processes often requires costly and time-consuming tests to evaluate different configurations. The 3D modeling presented thus offers a considerable advantage in terms of speed, efficiency, and profitability.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Mechanical Properties | |
---|---|
Density [g/cm3] | 1.4 |
E [MPa] | 3400 |
Poisson’s ratio | 0.3 |
Yield strengths for simple wall thickness (MPa) | 29 |
Yield strengths for double wall thickness (MPa) | 61 |
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Zarrouk, T.; Nouari, M.; Salhi, J.-E.; Abbadi, M.; Abbadi, A. Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure. Algorithms 2024, 17, 204. https://doi.org/10.3390/a17050204
Zarrouk T, Nouari M, Salhi J-E, Abbadi M, Abbadi A. Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure. Algorithms. 2024; 17(5):204. https://doi.org/10.3390/a17050204
Chicago/Turabian StyleZarrouk, Tarik, Mohammed Nouari, Jamal-Eddine Salhi, Mohammed Abbadi, and Ahmed Abbadi. 2024. "Three-Dimensional Finite Element Modeling of Ultrasonic Vibration-Assisted Milling of the Nomex Honeycomb Structure" Algorithms 17, no. 5: 204. https://doi.org/10.3390/a17050204