Numerical study on rotary ultrasonic machining (RUM) characteristics of Nomex honeycomb composites (NHCs) by UCSB cutting tool.

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 F_y 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. [ABSTRACT FROM AUTHOR]