超声插切Nomex蜂窝芯试验研究

Experimental Study on Ultrasonic Trepanning of Nomex Honeycomb Core

针对Nomex蜂窝芯构件中沿孔格轴向的轮廓边界加工复杂、质量不易控制等问题,在插切加工的基础上提出了一种超声插切的加工方法。开展了超声插切Nomex蜂窝芯试验研究,分别在刀具转速500~1500r/min和进给速度1000~3000mm/min下,进行了传统插切与超声插切的切削力测量和切口质量观测试验。试验结果表明,对比传统插切加工,振幅为20μm的超声插切加工在以上加工参数下均能有效降低切削力,平均降幅20%左右;超声插切加工Nomex蜂窝芯切口相对传统插切切口更加平顺、整齐、无毛刺。结合试验结果,进一步分析了刀具与工件在超声插切过程中的相对运动关系和切削力,从理论上解释了超声插切加工中切削力小和插切质量好的原因。

In order to solve the problems of complex machining and poor quality of the contour boundary along the axial direction in Nomex honeycomb core components,an ultrasonic trepanning method was proposed based on the trepanning process.The ultrasonic trepanning of Nomex honeycomb cores was carried out.Trepanning force measurement and incision quality observation tests were carried out under the tool spindle speed of 500–1500r/min and the feed speed of 1000–3000mm/min,respectively.The experimental results show that compared with the traditional trepanning process,the ultrasonic trepanning with the amplitude of 20μm can effectively reduce the trepanning force under the above machining parameters,with an average reduction of about 20%.The trepanning incision of Nomex honeycomb core processed by ultrasonic trepanning is smoother,more neat and without burrs than that of traditional trepanning.Combined with the experimental results,the relative motion relationship between the tool and the workpiece and the trepanning force during the ultrasonic trepanning process were further analyzed,and the reasons for the low trepanning force and good trepanning quality in ultrasonic trepanning process were theoretically explained.