Abstract
As compared to traditional milling, ultrasonic-assisted cutting of honeycomb core materials has the advantages of small cutting force and superior surface quality. Currently, ultrasonic straight blade V-shaped machining is one of the most efficient roughing processes. The requirement of a processing path to be post-processed based on the processing characteristics of the straight blade cutter is one of the key issues faced while meeting the technological requirements of CNC machine tools for V-shaped machining. A post-processing method of NC code for V-shaped machining of straight blade cutter is proposed in this article. Initially, the V-shaped rough machining process planning is done, followed by the usage of Unigraphics (UG) to output the initial CNC code. Next, the CNC code is executed through the three key technologies of the second arrangement of cutter locations. Later, research is done on information planning of lifting and lowering cutter, along with research on planning of chip breaking toolpath. Eventually, the simulation cutting experiment is carried out through VERICUT. The results demonstrate that the post-processing method can meet the processing requirements.
Highlights
In recent years, the automotive, aerospace, and defense industries have started choosing honeycomb cores as the core material for various high-performance and energy-absorbing structural components
To obtain a tool path with a small cutting depth and regular chips and to improve the cutting efficiency, modification of the tool path of odd and even layers must be done by planning the order of cutter location (CL)
The key steps are as follows: During the cutting process of “V” shape by using ultrasonic (1) Record the cutter location of chip breaker (CLCB)—The straight blade cutter as the processing tool, when the entire position of the tool path that needs to be added with chip
Summary
The automotive, aerospace, and defense industries have started choosing honeycomb cores as the core material for various high-performance and energy-absorbing structural components. A new BIUC (Blade-Inclined Ultrasonic Cutting) method for cutting a Nomex honeycomb core with a straight blade was proposed by Wang et al [11]. The geometric interference between the major flank and the machined surface can be reduced, which helps to reduce the deformation of the machined side and avoid crushing This method has higher requirements for tool path planning and CNC programs. Cui et al [12] proposed a path planning and generating method for V-shaped robotic cutting of Nomex honeycomb by straight blade tool. A straight blade cutter cuts twice with the same swing angle and inclination angle (in the tool coordinate system), and the cutting surface is formed into a “V” shape (triangle and diamond chips). 1⁄4 pffiffiffiffiffidffiffiffiffiffiffiffiffiffiffiffi; where tan αþsin θ d is the axial cutting depth of the tool, α is the yaw angle, θ is the rake angle (as shown in Fig. 4), and e is the blade thickness (refer to Fig. 3); (b) the margin is set to 0 mm; and (c) to align the starting tool paths of the upper and lower layers, the starting point of cutting is set at the corner with the largest vertical cutting amount of the blank
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