Abstract
A honeycomb structure is widely used in sandwich structure components in aeronautics and astronautics; however, machining is required to reveal some of its features. In honeycomb structures, deficiencies, such as burrs, edge subsiding, and cracking, can easily appear, owing to poor specific stiffness in the radial direction. Some effective fixation methods based on a filling principle have been applied by researchers, including approaches based on wax, polyethylene glycol, iron powder, and (especially) ice. However, few studies have addressed the optimization of the cutting parameters. This study focused on optimizing the cutting parameters to obtain a better surface roughness (calculated as a roughness average or Ra) and surface morphology in the machining of an aluminum alloy honeycomb by an ice fixation method. A Taguchi method and an analysis of variance were used to analyze the effects and contributions of spindle speed, cutting depth, and feed rate. The optimal cutting parameters were determined using the signal-to-noise ratio combined with the surface morphology. An F-value and P-value were calculated for the value of the Ra, according to a “smaller is better” model. Additionally, the optimum cutting parameters for machining the aluminum honeycomb by ice fixation were found at different levels. The results of this study showed that the optimal parameters were a feed rate of 50 mm/min, cutting depth of 1.2 mm, and spindle speed of 4000 r/min. Feed rate was the most significant factor for minimizing Ra and improving the surface morphology, followed by spindle speed. The cutting depth had little effect on Ra and surface morphology. After optimization, the value of Ra could reach 0.218 μm, and no surface morphology deterioration was observed in the verified experiment. Thus, this research proposes optimal parameters based on ice fixation for improving the surface quality.
Highlights
A honeycomb structure is widely used in aeronautics and astronautics, owing to its high stiffness-to-weight ratio, good rigidity, shock resistance, and superior insulation qualities [1, 2]
This study focused on the optimization of the cutting parameters, for obtaining the best combination of surface roughness and surface morphology
4.1 Cutting Parameters Optimization and Analysis According to the design of experiment (DOE), an L16(34) orthogonal array was arranged for the experiment. 16 groups of surface roughness values were measured using the ZYGO measurement system
Summary
A honeycomb structure is widely used in aeronautics and astronautics, owing to its high stiffness-to-weight ratio, good rigidity, shock resistance, and superior insulation qualities [1, 2]. It is especially useful in large components such as spacecraft landing gear, side bulkheads of spaceships, and rocket fairings [3]. Double-sided tape bonding is a method that uses double-sided tape to bond the workpiece and the fixture. This method cannot offer enough fixed force to fix the upper surface [9].
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