In-Depth Analysis of the Processing of Nomex Honeycomb Composites: Problems, Techniques and Perspectives
Abstract
:1. Introduction
- Material fragility: Honeycomb structures, especially composite ones, are often fragile and susceptible to fracture or deformation under high mechanical stresses.
- Optimization of processing parameters: It is crucial to determine the optimal machining conditions, such as cutting speed, ultrasonic frequency, and cutting angle, to minimize damage and maximize surface quality.
- Complexity of manufacturing processes: The integration of advanced technologies, such as ultrasonic cutting tools, requires precise calibration and a thorough understanding of tool–material interactions.
- Modeling and performance prediction: Developing theoretical and experimental models to predict the behavior of honeycomb structures under different machining conditions remains a major challenge.
- Designing innovative cutting tools: It is necessary to design high-precision cutting tools capable of working at microscopic scales while maintaining high surface quality.
- Tool Damage and Wear Management: Cutting tools used to machine honeycomb structures must be wear-resistant and capable of minimizing damage to the materials being machined.
2. Conventional Methods of Processing Nomex Honeycomb Composites (NHC)
2.1. Specific Machining Processes for Honeycomb Structures
2.2. Diversity of Tools for Machining Honeycomb Structures
2.3. Optimizing Machining Conditions for Improved Surface Quality
- Thermal: burning of the matrix, etc.
- Chemical: destruction of the fiber/matrix bonds, water uptake of the matrix.
- Mechanical: tearing of fibers, delamination, cracking of the material.
3. Machining of Nomex Honeycomb Composite Structure Assisted by Ultrasonic Vibrations
3.1. Ultrasonic-Assisted Straight-Blade Machining Systems
3.1.1. Analysis of the Characteristics of Straight Knife Processing on the Machinability of Nomex Honeycomb Composite Structures
- In the case of continuous processing, when the feed direction of the straight-blade cutting tool matches the speed direction vf during the entire cutting cycle, constant contact between the cutting tool and the workpiece is maintained during processing. In this situation, the feed rate equation can be formulated as follows:
- In the case of discontinuous processing, when the straight-blade cutting tool moves rapidly in the opposite direction to vf during a specific period of the ultrasonic cycle, periodic contact between the cutting tool and the workpiece occurs. This case can be described as follows:
3.1.2. Impact of Straight Knife Treatment on the Nomex Honeycomb Structure: Machined Surface Quality and Cutting Force
3.2. Ultrasonic-Assisted Circular Slope Machining Systems
3.2.1. Analysis of the Characteristics of Circular Knife Processing on the Machinability of Nomex Honeycomb Structures
3.2.2. Impact of Straight Knife Treatment on Nomex Honeycomb Structure: Machined Surface and Cutting Force
- Spindle speed impact: An increase in spindle speed results in a reduction in cutting force, due to the increase in the kinetic energy of the circular tool, which overcomes the propagation of cracks on the substrate surface. However, excessive spindle speed can raise the cutting temperature, potentially accelerating tool wear.
- Cutting width effect: By widening the cutting width, the contact surface between the cutting tool and the workpiece becomes larger, which increases the frictional resistance during the cutting process. This leads to an increase in the force required for cutting.
- Impact of feed rate: The cutting force increases with increasing feed rate, due to the increase in the volume of material removed per unit time. If the vibration amplitude remains constant, the propagation of cracks under the unit surface slows down, resulting in an increase in the required cutting force.
- Effect of vibration amplitude: At a higher vibration amplitude, the crack propagation length under the intermittent impact of the cutting tool will be longer, leading to a decrease in cutting force. Therefore, an increase in vibration amplitude results in a reduction in cutting force.
4. Conclusions
- Conventional processing technologies dominate the large-scale production of Nomex honeycomb structures in the aerospace, defense and automotive industries due to their simplicity. However, they are subject to tool wear, dust pollution, surface damage and machining defects. Thus, to improve the accuracy and quality of Nomex honeycomb composite structure treatments, research is turning towards the development of ultrasound treatment technologies.
- Ultrasonic machining is preferred for processing Nomex honeycomb composite structures due to the periodic contact between the cutting tool and the workpiece. The ultrasonic vibrations generated during contact reduce the cutting force, limit tool wear, minimize surface defects and ensure high surface quality. It is imperative to conduct in-depth research on the design parameters and the design of ultrasonic cutting tools, as well as ultrasonic cutting mechanisms, in order to effectively adapt them to the large-scale machining of Nomex honeycomb composite structures.
- Cutting conditions significantly impact the cutting force and surface quality of Nomex honeycomb composites. Increasing the feed rate, cutting width, and depth increases cutting force and decreases surface quality. Higher spindle speeds and vibration amplitudes improve surface quality and reduce cutting force. Straight knives are used for roughing, while circular knives are preferred for finishing, routing, flat surfacing and profiling, taking advantage of the superior benefits of ultrasonic longitudinal–torsional vibration in terms of surface quality and reduced cutting forces compared to ultrasonic longitudinal vibration.
- Machining defects and the surface quality of Nomex honeycomb structures vary between conventional machining and ultrasonic vibration-assisted machining, with the latter generally providing a better finish and fewer imperfections.
- The merging of ultrasonic processing systems with robotic arms signifies an advancing technology, yet its application in robotic machining is hampered by several errors. Geometric errors stem from the misalignment of robot workstations and disparities between nominal and actual kinematic parameter values. Non-geometric errors arise from environmental factors like temperature, humidity and dust, alongside issues like friction, limited controller bandwidth and insufficient manipulator robot rigidity.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Nomenclature
NHC | Nomex Honeycomb Composite Structure |
UVA | Ultrasonic Vibration-Assisted Machining |
CNC | Computer Numerical Control |
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Zarrouk, T.; Nouari, M.; Salhi, J.-E.; Essaouini, H.; Abbadi, M.; Abbadi, A.; Lahlaouti, M.L. In-Depth Analysis of the Processing of Nomex Honeycomb Composites: Problems, Techniques and Perspectives. Machines 2024, 12, 561. https://doi.org/10.3390/machines12080561
Zarrouk T, Nouari M, Salhi J-E, Essaouini H, Abbadi M, Abbadi A, Lahlaouti ML. In-Depth Analysis of the Processing of Nomex Honeycomb Composites: Problems, Techniques and Perspectives. Machines. 2024; 12(8):561. https://doi.org/10.3390/machines12080561
Chicago/Turabian StyleZarrouk, Tarik, Mohammed Nouari, Jamal-Eddine Salhi, Hilal Essaouini, Mohammed Abbadi, Ahmed Abbadi, and Mohammed Lhassane Lahlaouti. 2024. "In-Depth Analysis of the Processing of Nomex Honeycomb Composites: Problems, Techniques and Perspectives" Machines 12, no. 8: 561. https://doi.org/10.3390/machines12080561