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![Experimental milling setup of the Nomex honeycomb structure [14, 27]](publication/376161085/figure/fig3/AS:11431281215476255@1704250350920/Experimental-milling-setup-of-the-Nomex-honeycomb-structure-14-27_Q320.jpg)
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...
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Machining of Nomex honeycomb composite (NHC) structures is of critical importance in manufacturing parts to the specifications required in the aerospace industry. However, the special characteristics of the Nomex honeycomb structure, including its composite nature and complex geometry, require a specific machining approach to avoid cutting defects...
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Citations
... These studies aim to further analyze the NHC core wall-cutting process and evaluate how cutting conditions influence both machined surface quality and cutting forces [9,10]. Although cutting tool geometry has been optimized, conventional milling still faces significant challenges with respect to the cutting forces and quality of the machined surface, resulting in cell deformation and tearing of aramid fibers ( [11] remplacé par reference zarr). To overcome these problems, it is essential to develop more robust milling techniques and to precisely calibrate the optimal cutting conditions to minimize both cutting forces and improve the quality of the machined surface [12][13][14][15][16][17][18]. ...
Nomex honeycomb composite core (NHC) is characterized by thin walls and complex hexagonal cells, giving it specific characteristics. However, this particularity generates significant challenges during its shaping, requiring the use of cutting tools of the particular geometry. In this study, experimental tests were conducted on the milling of NHC structure assisted by RUM technology using the UCSB cutting tool which is a toothed milling cutter. However, the experimental procedure fails to follow the cutting process, which complicates the visualization of the chip formation process due to the rapid movement of the cutting tool and the inaccessibility of the surface between the part/tool. Therefore, in order to effectively follow chip formation, a 3D numerical approach to the milling process of the NHC structure, using RUM technology, is developed using Abaqus Explicit software. On the basis of this model, the study focused on the components of the cutting force, the quality of the machined surface, and the accumulation of chips in front of the cutting tool. The numerical simulation results corroborate the experimental test findings, demonstrating the effectiveness of RUM technology in reducing cutting force components by up to 63%. An exhaustive analysis of the impact of the feed component Fy on the quality of the surface obtained was carried out, highlighting that the quality of the generated surface improves when the values of this component are low. In addition, the effectiveness of ultrasonic vibrations in reducing the accumulation of chips in front of the cutting tool is particularly accentuated, especially when large amplitudes are involved. Thus, the simulated results complemented the experimental results by offering coherent theoretical explanations.
