Title: Study on tearing defects in high-speed milling of aluminium honeycomb core

Authors: Hualin Zheng; Haoran Zhang; Huan Chen

Addresses: School of Mechatronic Engineering, Southwest Petroleum University, Chengdu, China ' School of Mechatronic Engineering, Southwest Petroleum University, Chengdu, China ' School of Mechatronic Engineering, Southwest Petroleum University, Chengdu, China

Abstract: The tearing defect generated during the processing of aluminium honeycomb core is one of the main factors to reduce the bonding strength between the aluminium honeycomb core and connective face sheet. In order to study the tearing defects formed during high-speed milling of aluminium honeycomb cores, a finite element model for cutting a single honeycomb wall was established. The influence of main processing parameters on tearing defects was explored, and the variation law between tearing defects and cutting forces under different processing parameters was further analysed. The results show that when the entrance angle is in regions I and III, the force F_|| parallel to the honeycomb wall is the main reason for the formation of tearing defects. When the entrance angle is in region II, the force F_⊥ perpendicular to the honeycomb wall has a great influence on the tearing defect. The degree of tearing defects is positively correlated with the force F_|| parallel to the honeycomb wall in general, and the influence on tearing defects follows that the entrance angle > feed speed > cutting speed.

Keywords: aluminium honeycomb core; finite element simulation; cutting force; tearing defect; milling parameter.

DOI: 10.1504/IJMMM.2025.145075

International Journal of Machining and Machinability of Materials, 2025 Vol.27 No.1, pp.4 - 18

Received: 06 Sep 2023
Accepted: 01 Dec 2023
Published online: 18 Mar 2025 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article