applied

sciences
Article
Cutting Force Prediction and Experiment Verification
of Paper Honeycomb Materials by Ultrasonic
Vibration-Assisted Machining
Wenjun Cao 1 , Jun Zha 1,2 and Yaolong Chen 1, *
1 School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China;
caowenjun17@stu.xjtu.edu.cn (W.C.); jun_zha@xjtu.edu.cn (J.Z.)
2 Shenzhen Research School, Xi’an Jiaotong University, Hi-Tech Zone, Shenzhen 518057, China
* Correspondence: chenzwei@mail.xjtu.edu.cn; Tel.: +86-029-83-39-95-11




Received: 19 May 2020; Accepted: 3 July 2020; Published: 7 July 2020


Abstract: The disc-cutter is a finishing tool for the ultrasonic-cutting of paper honeycomb-core
material. The cutting state directly affects the machining accuracy and surface quality of the
workpiece. The cutting force is an important physical quantity and the cause of ultrasonic cutting
defects of the honeycomb-core material. Due to differences in the mechanical properties and
cutting performance of honeycomb-core materials and commonly used metal materials, existing
metal-cutting-force models cannot be applied to the calculation of ultrasonic cutting forces in the
processing of honeycomb-core materials. In response to this problem—combined with actual working
conditions using the ABAQUS finite element analysis software—a finite element simulation model
of the ultrasonic vibration-assisted cutting force of the disc-cutter on the honeycomb-core material
was established, and the cutting curves and values were obtained. The experiment of ultrasonic
vibration cutting of the disc-cutter proves that from the surface morphology of the honeycomb core,
the milling-width has the greatest influence on the cutting force, and the cutting-depth has the smallest
influence on the cutting force. The maximum error between the cutting force experimental results
and the finite element simulation results under the same cutting conditions was 13.2%, which means
that the established cutting-force finite element model is more accurate and can be used to predict
the cutting in honeycomb ultrasonic vibration-assisted cutting-force value. Finally, based on the
response surface method, a three-dimensional cutting force prediction model of the ultrasonic cutting
honeycomb core of the disc-cutter was established by using the simulation model data. The results of
this study can provide a useful basis for the improvement of cutting performance and processing
efficiency in the processing of paper honeycomb-core materials.

Keywords: honeycomb core; disc-cutter; ultrasonic vibration-assisted; finite element analysis

1. Introduction
Honeycomb-core material is a kind of high-stiffness, light-quality, heat-resistant, impact-resistant,
fatigue-resistant, good-insulating soundproof stays-engineering composite material. Zuhri, Gomet
and Castaniea analyzed the mechanical properties and excellent qualities of honeycomb-core materials
through theoretical modeling and experimental verification [1–3]. Alix and Tauhiduzzaman introduced
honeycomb parts used in the aerospace field such as helicopter power plant fairings, large aircraft
wings, liquid fuel barriers in rockets, etc. [4,5]. In order to meet the requirements of assembly and
connection, the honeycomb-core material must be cut after it is formed. However, the honeycomb-core
material is a typical difficult to machine material, it brings great challenges to the CNC machining of
honeycomb-core material due to the particularity of honeycomb core structure and cutting mechanism.

Appl. Sci. 2020, 10, 4676; doi:10.3390/app10134676 www.mdpi.com/journal/applsci

Appl. Sci. 2020, 10, 4676 2 of 16

Rinker, Malek and Hohe proposed related process optimization methods for processing defects such
as honeycomb core fracture and collapse, increased surface burrs and dust pollution during the
CNC high-speed milling process of honeycomb core, which greatly reduces the performance of the
honeycomb core structure and improves the product Safety and service life [6–8].
Oriented to the manufacturing requirements of honeycomb-core material parts, in view of the
problems existing in CNC high-speed milling processing, scholars are constantly exploring new
processing methods and improving the existing processing technology. Ultrasonic vibration-assisted
cutting technology as a new advanced processing technology has been applied in the field of CNC
machining of honeycomb core workpiece [9]. Compared with high speed milling, this machining
method has significant advantages in machining accuracy, quality, efficiency and environmental
friendliness [10,11]. In the ultrasonic vibration-assisted machining of honeycomb-core material, there
still have surface damage problems such as core tearing and machining surface burr. There is little
research on the ultrasonic vibration-assisted cutting force of the disc-cutter. Heimbs and Aminanda
studied the failure behavior of the honeycomb core through experimental means and concluded
that the cutting force is an important physical parameter that causes defects in the honeycomb
core workpiece [12,13]. The research of rotating vibration cutting of honey comb core components
with disc-cutter is only focusing on the test verification; mechanism study must be carried out to
reveal the influence of the cutting parameters on machining quality. Potlkuri measured the elastic
properties of the hexagonal honeycomb-core material through experiments [14]. Based on brittle
fracture mechanics, Hu studied the cutting mechanism of the ultrasonic cutting of the honeycomb core
with a sharp knife and derived a theoretical model of cutting force [15]. However, the entire process
of ultrasonic vibration-assisted cutting of disk cutters is time-consuming, the processing quality is
unstable, the surface burrs on the processing, and the core damage are still outstanding.
In order to solve the problem of cutting damage of the honeycomb core workpiece in ultrasonic
vibration-assisted cutting, this study used finite element analysis software to establish a 3D
honeycomb-core material model and a disc-cutter model according to the actual working conditions.
A method of ultrasonically cutting the honeycomb-core material with a disk milling cutter is proposed.
At the same time, the correctness of the finite element model is verified through experiments.
The influence of process parameters on cutting quality was studied. At the same time, based on the
response surface method, a simulation model was used to construct a cutting force prediction model
for the honeycomb core of the disc-cutter ultrasonic machining, which provided a theoretical basis
for the optimization of the cutting technology of the honeycomb-core material and the reasonable
selection of processing parameters.

2. Establishment and Verification of Finite Element Simulation Model for Honeycomb Core
Ultrasonic Vibration-Assisted Cutting

2.1. Disc-cutter Geometry Model

Due to the structure difference between Nomex honeycomb-core composite material and the
metal material, a corresponding special tool must be used for machining, and the structural shape
and geometric angle of the tool are greatly different from the metal cutter. Nomex honeycomb-core
composites material can be machined due to the tool forms a sharp cutting edge with a small wedge
angle, which is the key to the material being cut. The rotary-vibration-cutting disc-cutter model studied
in this paper is shown in Figure 1. Due to the complex structure of the tool, the model was built by the
CATIA V5R21 and imported into the ABAQUS, the geometric parameters of disc-cutter are shown in
Table 1.
 Height of tool 5 mm
inner diameter of tool 12 mm

The tool material is W18Cr4 V, material density ρ = 7900 kg/m3, elasticity modulus E = 205 Gpa,
Poisson’s ratio
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to the low hardness of the Nomex honeycomb-core material, the tool wear
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Appl. Sci. 2020, 10, 4676 3 of 16
is neglected in the simulation, and the tool is defined as a rigid body.
Table 1. Geometric parameters of disc-cutter.

Features of the Model Parameter

Cutter diameter 50.8 mm
Angle of wedge 14°
Height of tool 5 mm
inner diameter of tool 12 mm

The tool material is W18Cr4 V, material density ρ = 7900 kg/m3, elasticity modulus E = 205 Gpa,
Poisson’s ratio μ = 0.3. Due to the low hardness of the Nomex honeycomb-core material, the tool wear
is neglected in the simulation, and the tool is defined as a rigid body.
Figure 1. Disc-cutter geometry model.
Figure 1. Disc-cutter geometry model.
Table 1. Geometric parameters of disc-cutter.
2.2. Honeycomb Core Geometry Model and Material Model
Features of the Model Parameter
The honeycomb-core material is structurally different from the conventional metal-processing
Cutter diameter 50.8 mm
material. It is a porous thin-walled structure
Angle of wedgewith a hexagonal shape, 14◦ the hole has a side length of 3–
6 mm and a single-layer-wall thicknessHeightofof0.05–0.15
tool mm. Honeycomb 5 mmcore geometry modeling is per-
formed in ABAQUS/CAE, where a single
inner core
diameter is drawn, then the12entire
of tool mm sketch is completed by mir-
roring and arraying, and finally stretched vertically along the aperture according to the height of the
desiredThehoneycomb core.
tool material When the
is W18Cr4 wall thickness
V, material density ofρthe shellkg/m
= 7900 unit3is set, the thickness
, elasticity modulus of
E= the
205single
Gpa,
layer is set to 0.1 mm, and the thickness of the double layer joint is 0.2 mm. The geometric
Poisson’s ratio µ = 0.3. Due to the low hardness of the Nomex honeycomb-core material, the tool wear model of
the Nomex honeycomb-core composite
is neglected in the simulation, and material
the tool
Figure established
is definedgeometry
1. Disc-cutter in
as a rigid the
body.
model. finite element analysis is shown
in Figure 2.
2.2. Honeycomb
Honeycomb Core Geometry Model and Material Model
The honeycomb-core material is structurally different from the conventional conventional metal-processing
material. ItItisisaaporous
porousthin-walled
thin-walledstructure
structurewith
witha ahexagonal
hexagonal shape,
shape, thethe hole
hole hashas a side
a side length
length of
of 3–
63–6
mmmm andand a single-layer-wall
a single-layer-wall thickness
thickness of 0.05–0.15
of 0.05–0.15 mm.mm. Honeycomb
Honeycomb corecore geometry
geometry modeling
modeling is
is per-
performed in ABAQUS/CAE, where a single core is drawn, then the entire sketch
formed in ABAQUS/CAE, where a single core is drawn, then the entire sketch is completed by mir- is completed by
mirroring
roring andand arraying,
arraying, andand finally
finally stretched
stretched vertically
vertically along
along the the aperture
aperture according
according to the
to the heightheight of
of the
the desired
desired honeycomb
honeycomb core.
core. When
When thethe wall
wall thickness
thickness ofof the
the shellunit
shell unitisisset,
set,the
thethickness
thickness of
of the
the single
layer is set to 0.1 mm, and the thickness of the double layer joint is 0.2 mm. The geometric model of
the Nomex honeycomb-core
honeycomb-corecomposite
compositematerial
materialestablished
establishedininthe
thefinite
finiteelement
elementanalysis
analysisis shown
is shown in
Figure
in 2. 2.
Figure

Figure 2. Nomex honeycomb-core composite geometry model.

Figure 2. Nomex honeycomb-core composite geometry model.

Figure 2. Nomex honeycomb-core composite geometry model.
Appl. Sci. 2020, 10, 4676 4 of 16

The main structure of Nomex honeycomb core is aramid paper. The molding of aramid paper
material is made by arranging aramid fibers randomly distributed in XYZ direction in any ratio and
combining them. Due to the flexibility and randomness of fiber arrangement, the mechanical properties
of Nomex honeycomb-core materials cannot be directly measured by researchers using conventional
measurement methods. To date, the more commonly used is derived from the empirical formula of the
fiber modulus at random. The research shows that the mechanical properties of the aramid fiber in
the vertical direction are basically consistent with the main direction of the material. In this paper,
the honeycomb material and tool material used in cutting simulation processing The attributes are
shown in Table 2 below.

Table 2. Tool and honeycomb material properties [16,17].

Elastic Poisson’s Thermal Expansion Thermal Specific Heat

Density
Material Modulus Ratio Coefficient Conductivity Capacity
ρ (kg/m3 )
E/Gpa σ 10−6 /◦ C W/(m·◦ C) J/(kg·◦ C)
W18Cr4 V high speed steel 7800 210 0.3 4.5 24 420
Nomex honeycomb core 1334 2.01 0.25 4 0.123 1300

2.3. Separation and Fracture Failure Criteria

The ultrasonic vibration-assisted cutting process of honeycomb-core material is the separation
process of chip and workpiece under the action of blade and ultrasonic vibration-assisted.
Therefore, the determination of chip separation and fracture failure criteria is critical to achieving finite
element simulation of the honeycomb core cutting process. The separation criteria depend on the
mechanical and physical properties of the material. Common separation criteria are geometric and
physical criteria. The shear-failure criterion is applied in this study, which is provided by the finite
element software. Depending on the plastic strain value of the element node reaches a predetermined
critical value to determining failure occurs or not. By the calculation, when the destruction coefficient
ω reaches the set value, the unit is considered to be “killed”, which means the material is destroyed and
chips are formed. The value of the failure coefficient ω can be obtained from the following formula:

X ∆εpl
ω= pl
(1)
εf

pl
where ∆εpl is the equivalent plastic strain increment; ε f is the total strain when the material is damaged;
w is the shaping limit value or destruction coefficient.

2.4. Meshing, Boundary Conditions and Load Settings

In this paper—based on the Hypermesh software—the honeycomb-core material in the processing
path of the disc-cutter was locally refined and sharpened. The honeycomb core was is meshed with
C3D8T eight-node thermal coupling hexahedron, and the disc-cutter uses C3D10MT ten-node thermal
coupling second-order tetrahedron meshing. The divided honeycomb core is imported into ABAQUS.
Since the calculation of cutting heat is considered, an explicit temperature–displacement algorithm
is selected. Before the model is submitted to the calculation, carefully check the setting of nonlinear
parameters that may lead to nonconvergence or difficult convergence, Such as material settings, contact
settings, etc.
During the simulation, the disk cutter and the honeycomb core must be subjected to load and
boundary condition constraints according to the actual working conditions. Since the stiffness of the
disc-cutter is much greater than that of the honeycomb core, the cutter is used as a rigid body during
the simulation. In terms of boundary constraints, due to the poor local strength of the honeycomb core,
it is not possible to use the traditional method of holding. In actual working conditions, the part is
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is
is held
held by vacuum suction through adhesive tape on the bottom surface of the part. In the simulation
held byby vacuum
vacuum suction
suction through
through adhesive
adhesive tape
tape ononthethebottom
bottomsurface
surfaceof ofthe
thepart.
part.In Inthe
thesimulation
simulation
model,
model, it itit is assumed
is assumed
assumedthat that
thatthethe part
thepart
partisis held
isheld firmly.
heldfirmly. All
firmly.All joints
Alljoints
jointson on the
onthe bottom
thebottom
bottomof of the
ofthe part
thepart are
partare fully
arefully fixed.
fullyfixed.
fixed.
model, is
The
The disc-cutter
disc-cutter has
has three
three directions
directions of
of motion
motion synthesis
synthesis relative
relative to
to the
the honeycomb
honeycomb material,
material,
The disc-cutter has three directions of motion synthesis relative to the honeycomb material, which
which
which are the feed
feed movement, rotary
rotary movement of
of the cutter along its cutting
cutting trajectory and
and the
the vi-
are the are
feedthe movement, movement,
rotary movement movement
of the cutter the cutter
along its along
cuttingitstrajectory trajectory
and the vibration vi-
of
bration
bration of the
ofalong cutter
the cutter along
along its axis. Velocity/angular
its axis. Velocity/angular velocity was adopted in ABAQUS The disc-cutter
the cutter its axis. Velocity/angular velocity wasvelocity
adopted was adopted inThe
in ABAQUS ABAQUS Thedefines
disc-cutter disc-cutter
the
defines
defines the
the feed
feed velocity
velocity (vf) along the x-axis and thethe rotary motion along the z-axis,
z-axis, while applying
feed velocity (vf) along the(vf) along
x-axis andthethex-axis
rotaryand motion rotary
along themotion along
z-axis, while theapplying while applying
a reciprocating
aa reciprocating
reciprocating ultrasonic wave up and down
down to the
the periodic amplitude function of the
the Fourier series
ultrasonic waveultrasonic
up and down waveto upthe
andperiodic to periodic
amplitude amplitude
function of thefunction
Fourierof series Fourier series
in the z-axis
in
in the
the z-axis
z-axis direction
direction of
of the
the disc-cutter
disc-cutter vibration.
vibration. Set
Set the
the initial
initial temperature
temperature of
of parts,
parts, disc-cutter
disc-cutter and
and
direction of the disc-cutter vibration. Set the initial temperature of parts, disc-cutter and environment
environment
environment to room temperature.
to room temperature. The
The simulation
simulation model
model of Nomex
of Nomexcore honeycomb
honeycomb core with
core with ultrasonic
ultrasonic
to room temperature. The simulation model of Nomex honeycomb with ultrasonic vibration of
vibration
vibration of ofisdisc-cutter
disc-cutter is
is shown
shown in Figure 3.
disc-cutter shown in Figure 3. in Figure 3.

Figure 3. Nomex simulation model of ultrasonic vibration cutting of disk cutter.

Figure 3. Nomex
Figure 3. Nomex simulation
simulation model
model of
of ultrasonic
ultrasonic vibration
vibration cutting
cutting of
of disk
disk cutter.
cutter.

In
In the
the direction
direction of
of the
the z-axis
z-axis of of the
the tool,
tool, the
the vibration
vibration equation
equation of
of any
any node
node of
of the
the disc-cutter
disc-cutter
during rotary-vibration-cutting
during rotary-vibration-cutting is: is:
zi = A sin(2π f t) (2)
i sin(22ππftft))
zzi == AAsin( (2)
(2)
where A is the amplitude (µm); f is the frequency (Hz).
where
The
where A
A is
is the
the amplitude
periodic amplitude
amplitude (μm); ff is
function
(μm); is the frequency
thein the formula
frequency (Hz).
(Hz).is expressed by Fourier series, and loaded in
The
ABAQUS periodic amplitude
in the form
The periodic function
of Figurefunction
amplitude in
4, the expressionthe formula
is:
in the formula is
is expressed
expressed by
by Fourier
Fourier series,
series, and
and loaded
loaded inin
ABAQUS in the form of Figure 4, the
ABAQUS in the form of Figure 4, the expression is:expression is:
N
N


X
N [A cos nω(t − t ) + B sin nω(t − t )]
aa == AA00 ++ [[AAn ncos
a = A + nω (t − t00 ) + Bnn sin nω (t − 0t0 )] (3)
0 
n=1 n cos nω (t − t 0 ) + Bn sin nω (t − t 0 )]
n =1
n =1
(3)
(3)

where
where A00 is the initial amplitude (µm); ω isisthe circular frequency (rad/s); AnAisn the coefficient of the cos
where A A0 is
is the
the initial
initial amplitude
amplitude (μm);
(μm); ω ω is the
the circular
circular frequency
frequency (rad/s);
(rad/s); An is
is the
the coefficient
coefficient of
of the
the
function;
cos Bn is thethe coefficient of the sin sin
function.
cos function;
function; BBnn is
is the coefficient
coefficient of
of the
the sin function.
function.

Figure 4. Schematic diagram of the rotary vibration amplitude loading of disc-cutter.

Figure 4. Schematic
Schematic diagram
diagram of
of the
the rotary vibration amplitude loading of disc-cutter.

2.5.
2.5. Simulation
Simulation Scheme
Scheme Design
Design
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2.5. Simulation Scheme Design
In actual cutting, the disc-cutter cannot cut with large margin in the radial direction without
crushing chip,
crushing chip, otherwise
otherwisethe
theresidual
residualmaterial
materialcannot
cannotbebe
cutcut
off,off,
thethe
workpiece
workpiecewillwill
be pulled up and
be pulled up
causing cutting damage. The disc-cutter must be processing according to the depth and
and causing cutting damage. The disc-cutter must be processing according to the depth and width width pro-
duced by knife
produced cutting.
by knife TheThe
cutting. specific cutting
specific is shown
cutting in Figure
is shown 5. 5.
in Figure

aapp
aaee
vvff

Figure 5.
Figure 5. Schematic
5. Schematic
Schematic diagram
diagram of of
of
diagram ultrasonic
ultrasonic vibration-assisted
vibration-assisted
ultrasonic cutting
cutting
vibration-assisted of Nomex
of
cuttingNomex honeycomb-core
honeycomb-core
of Nomex com-
com-
honeycomb-core
posite material.
posite material.
composite material.

In order
order to
to ensure
ensurethe
thefeasibility
feasibilityofofthe
theexperiment,
experiment,first, use
first, thethe
use knife cutter
knife to produce
cutter thethe
to produce cutting
cut-
ting thickness
thickness and width
and width for disk
for disk cutter
cutter processing,
processing, andand
thenthen
use use
the the
diskdisk cutter
cutter to machine
to machine thethe pro-
profile.
The
file. cutting process
The cutting is shown
process in Figure
is shown 6. 6.
in Figure

vvff

aaee

aapp

Figure 6.
Figure
Figure 6. Disc-cutter ultrasonic vibration-assisted cutting scheme.
6.

In order
In order toto ensure
ensurethe
theconsistency
consistencyofofthe
thecutting
cuttingsimulation
simulation and
andthethe
cutting experiment
cutting experiment parameters,
parame-
as well
ters, as the
as well as accuracy of subsequent
the accuracy testtest
of subsequent verification.
verification. Since the
Since thefollow-up
follow-uptest
testisisverified
verified on
on the
the
designated
designated ultrasonic
ultrasonic processing
processing equipment,
equipment, the the spindle
spindle speed
speed and
and amplitude must be kept constant.constant.
According
According to tothe
theactual
actualprocessing
processingconditions
conditions on on
site,site,
technicians usually
technicians adjust
usually the cutting
adjust widthwidth
the cutting range
from
range5from
to 20 5mm.
to 20The
mm.cutting depth ranges
The cutting from 5 from
depth ranges to 20 mm, and
5 to 20 mm,theand
feedthe
speed
feedranges
speed from
ranges3000 to
from
6000 mm/min under the conditions of speed n = 1500 r/min and amplitude
3000 to 6000 mm/min under the conditions of speed n = 1500 r/min and amplitude A = 30 μm, mayA = 30 µm, may wish to
obtaintothe
wish single-factor
obtain simulation
the single-factor programprogram
simulation shown inshownTable 3inthrough
Table 3reasonable design and
through reasonable planning.
design and
planning.
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Table 3. Single factor simulation scheme for ultrasonic vibration-assisted cutting of disk cutter.
Table 3. Single factor simulation scheme for ultrasonic vibration-assisted cutting of disk cutter.
Number Cutting Width (mm) Cutting Depth (mm) Feed Speed (mm/min)
Number Cutting Width (mm) Cutting Depth (mm) Feed Speed (mm/min)
1 5 5 3000
1 5 5 3000
2 2
8.75 8.75 8.75
8.75 3750
3750
3 3 12.5 12.5 12.512.5 4500 4500
4 4 16.25 16.25 16.25
16.25 5250 5250
5 5 20 20 20 20 6000 6000

3. Results
3. Results
3.1. Simulation Results and Verification Analysis
3.1. Simulation Results and Verification Analysis
In addition to the above key links, the rotational vibration simulation analysis of the disc-cutter
In addition to the above key links, the rotational vibration simulation analysis of the disc-cutter
must set the field output results and historical output results in the software, such as stress, strain,
must set the field output results and historical output results in the software, such as stress, strain,
displacement, energy, temperature, etc. At the same time, in order to improve the calculation effi-
displacement,
ciency, theenergy, temperature,
honeycomb-core etc. At material
composite the sameistime, inby
scaled order to improve
5 times the calculation
in the simulation efficiency,
to reduce the
the honeycomb-core composite material is scaled by 5 times in the simulation to reduce the
calculation time. The finite element simulation process of Nomex honeycomb-core composite disc- calculation
time.cutter
The finite element
rotating simulation
vibration cutting isprocess
shown ofin Nomex
Figure 7.honeycomb-core composite disc-cutter rotating
vibration cutting is shown in Figure 7.

Figure
Figure 7. Rotary-vibration-cuttingsimulation
7. Rotary-vibration-cutting simulation of
ofdisc-cutter.
disc-cutter.
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Figure
Figure 88 is
is aaschematic
schematic diagram
diagram showing
showing thethe cutting
cutting force
forcevariation
variationcurve.
curve. Where
Where the
the spindle
spindle
speed the cutting depth a = 5 mm, the cutting width a =
speed is 1500 r/min, the cutting depth ap p = 5 mm, the cutting width aε ε = 10 mm, Feedingspeed
is 1500 r/min, 10 mm, Feeding speedvvf f==
3000
3000 mm/min,
mm/min,the thevibration
vibrationfrequency
frequencyis is20,000
20,000Hz,
Hz, thethe
ultrasonic
ultrasonicvibration-assisted
vibration-assisted amplitude
amplitudeA =A30=
µm, and the simulation acquisition frequency is 600 Hz. It can also be seen from
30 μm, and the simulation acquisition frequency is 600 Hz. It can also be seen from figure that during figure that during the
cutting process, the maximum and minimum values of the cutting force in
the cutting process, the maximum and minimum values of the cutting force in three directions fluc- three directions fluctuate
greatly. On oneOn
tuate greatly. hand,
one the reason
hand, is that the
the reason Nomex
is that honeycomb
the Nomex core is not
honeycomb corea is
completely homogeneous
not a completely homo-
structure.
geneous structure. When the tool is processed to the honeycomb hole At the time, the required force
When the tool is processed to the honeycomb hole At the time, the required cutting is
cutting
small,
force isand when
small, and thewhen
tool is
theprocessed to the bonding
tool is processed point of the
to the bonding honeycomb
point hole wall,hole
of the honeycomb the required
wall, the
cutting
required cutting force is large. The other reason is that due to the frictional resistance of and
force is large. The other reason is that due to the frictional resistance of the upper lower
the upper
surfaces of the disc-cutter and the honeycomb core, the cutting direction of
and lower surfaces of the disc-cutter and the honeycomb core, the cutting direction of the cutter the cutter is different fromis
the direction of the reaction force of the honeycomb core in the feed direction, so
different from the direction of the reaction force of the honeycomb core in the feed direction, so that that each cutting The
conditions
each cutting forThe
chip removal are
conditions for also
chipdifferent
removal at areallalso
times.
different at all times.
(N)

(N)

(s) (s)

(a) Cutting force variation in X direction (b) Cutting force variation in Y direction
(N)

(s)

(c) Cutting force variation in Z direction

Figure 8.
Figure 8. Simulation of cutting force changing curve by
by rotating
rotating vibration
vibration of
of the
the disc-cutter.
disc-cutter.
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3.2. Verification
3.2. Verification of Ultrasonic
Verification of Ultrasonic Vibration-Assisted
Vibration-Assisted Cutting
Cutting Simulation
Simulation Model
Model
In order
In order toto verify
verify the
the accuracy
accuracy of of thethe finite
the finite element
finite element
element model,model,
model, the the simulation
the simulation scheme
simulation scheme
scheme in in Table
Table 33 was
in Table was
used to conduct cutting experiments on
used to conduct cutting experiments on honeycomb-core honeycomb-core
honeycomb-core materials, materials,
materials, and and the simulation
and the simulation resulted
simulation resulted of of
cutting force
cutting force were
were compared
compared with with the
the experimental
experimental results.
experimental results.
results.
The ultrasonic vibration cutting experiment
The ultrasonic vibration cutting experiment of the Nomex of the Nomex honeycomb-core
honeycomb-core composite
composite material
material
was carried
was carriedout
carried outon
out onthe
on theadvanced
the advanced
advanced ultrasonic
ultrasonic
ultrasonic processing
processing
processing machine
machine
machine US-50US-50
US-50 produced
produced
produced by the byAustrian
by the Austrian
the Austrian
GFM
GFM
GFM
company.company.
company. The measurement
The measurement
The measurement of the
of theforce
of the cutting cutting
cutting
in theforce
force in the experiment
in the experiment
experiment was performed was
was by performed
performed by the
by the
the Kistler9257B
Kistler9257B
Kistler9257B dynamic
dynamic forcedynamic
measurementforce measurement
force measurement system.
system. In thesystem.test, the InIn
datathe test, the
theacquisition data
test, the data acquisition
acquisition
frequency frequency
was frequency
4000 Hz, the was
was 4000
4000
Nomex
Hz,
Hz, the Nomex
the Nomex honeycomb-core
honeycomb-core honeycomb-core
material used in the material
material
test was used
used in the
in the test
NRH-3–48, test
andwas
was NRH-3–48,
theNRH-3–48, and
sample sizeand the
wasthe sample
100sample
mm × 80 size
sizemmwas
was×
100
100 mm × 80 mm
mm × 80 mm × 60 mm.
60 mm. × 60 mm.
The cutting
The cutting force
force measurement
measurement principleprinciple is is shown
shown in in Figure
Figure 9. 9. The
The basic
The basic principle
basic principle
principle is is that the
is that the
voltage analog
voltage analog signal
signal ofof the
the cutting
cutting force
force in in three
three directions
directions is is first
first measured
measured by by the
the Kistler9275B
Kistler9275B
three-way
three-way dynamometer, and then the
three-way dynamometer, and then the signal is collectedsignal is collected by the quasi-static
collected by the quasi-static charge
quasi-static charge amplifier,
charge amplifier, data data
acquisition
acquisition card and
acquisition card and chassis.
chassis. Then,
Then,
Then, itit is converted
it is converted into into numeric
numeric signals
signals by
by data-acquisition
data-acquisition virtual virtual
instrument
instrument software
instrument software
software forfor data
fordata storage
datastorage
storageand and analysis
andanalysis by
analysisbybythe the computer,
thecomputer,
computer, and
and finally
finally
and the
thethe
finally average
average
average value
value of
of
value
the
the collected
collected
of the collectedcutting
cutting
cuttingforce
force signals
signals
force is used
is used
signals is usedas the
as the
as thecutting
cutting
cutting force
forceforceduring
during the processing.
thethe
during processing.
processing. During
DuringDuringthe ex-
the the
ex-
periment,
periment,
experiment, each
each group
group
each group ofof
of process
process parameters
processparameters
parametersare are tested
aretested twice,
testedtwice, and
twice,and the
andthe average
theaverage value
averagevalue
valueis is taken
istaken to
taken to ensure
to ensure
ensure
the reliability
the reliability ofof the
the experimental
experimental data.data. The The specific
specific processing
processing environment
environment is is shown
shown in in Figure
Figure 10.
Figure 10.
10.

Figure 9.
Figure 9. Cutting-force
Cutting-force measurement
Cutting-force measurement principle.
measurement principle.

Figure 10.
Figure Overview of
10. Overview of experimental
experimental devices.
devices.
Appl. Sci. 2020, 10, 4676 10 of 16
Appl. Sci. 2020, 10, x FOR PEER REVIEW 10 of 16

During the
During the experiment,
experiment, the the spindle
spindle speed
speed was
was 1500
1500 r/min
r/min and
and the
the feed
feed rate
rate was
was 4500
4500 mm/min.
mm/min.
There were 8 groups of experiments, 4 groups of cutting width experiments
There were 8 groups of experiments, 4 groups of cutting width experiments and 4 groups of and 4 groups of cutting
cutting
depth experiments.
depth experiments.
As shown in
As shown in Figure
Figure11,11,the
thesurface
surfacetopography
topographyofofaeae==55mmmmwas wasobviously
obviouslybetter
better than
than that
that of of ae
ae =
= 10
10 mm.There
mm. There were
were a large
a large number
number of of burrs
burrs on on
thethe surface
surface whenwhen
thethe constant
constant waswas 10 mm,
10 mm, in addition
in addition to a
to a large number of burrs; the regular hexagon on the surface also had serious distortion.
large number of burrs; the regular hexagon on the surface also had serious distortion. It could be seen, It could be
seen, with the increase of cutting depth ap, the surface morphology of honey comb core material be-
with the increase of cutting depth ap , the surface morphology of honey comb core material became better.
came better.
When ap = 40When
mm the ap surface
= 40 mm of the
the surface
materialofhadthealmost
material had almost
no burrs, nosurface
and the burrs, hexagon
and the surface hexa-
was regular.
gon was regular.

(a1) ap = 10 mm (a2) ap = 20 mm

(a3) ap = 30 mm (a4) ap = 40 mm

(b1) ap = 10 mm (b2) ap= 20 mm

Figure 11. Cont.

Appl. Sci. 2020, 10, 4676 11 of 16
Appl.
Appl. Sci.Sci. 2020,
2020, 10,10, x FORPEER
x FOR PEERREVIEW
REVIEW 11 of
1116
of 16

(b3) ap= 30 mm (b4) ap = 40 mm

(b3) ap= 30 mm (b4) ap = 40 mm
Figure 11. Honeycomb-core material topography. (a) Honeycomb-core material morphology (cutting
Figure
width11.
ae =Honeycomb-core material
material topography.
5 mm); (b) honeycomb-core
Honeycomb-core (a) Honeycomb-core
material morphology
topography. material
(cutting width
Honeycomb-core ae = 10morphology
mm). (cutting
width aee ==55mm);
mm);(b)
(b)honeycomb-core
honeycomb-core material
material morphology
morphology (cutting width aaee ==10
(cutting width 10mm).
mm).
Based on the change curve of the cutting force under different machining parameters obtained
by Based on the
the change
actual cutting curve
experiments,
change curvethe of
ofthe
thecutting
cuttingforce
simulation data
force under
of different
the vibration
under machining
cutting
different of theparameters
machining disc-cutter
parameters obtained
was com- by
obtained
by pared
actual
actual and
cutting analyzed.
experiments,
cutting The
experiments, experimental
the simulation data
the simulationofdata were obtained
the vibration by the three-dimensional
cutting cutting
of the vibration of the disc-cutter dynamometer.
was compared
of the disc-cutter was com-and
The simulation
analyzed.
pared andThe dataThe
experimental
analyzed. wereexperimental
obtained
data wereby the
datareaction
obtained by the
were force of the tool three-dimensional
three-dimensional
obtained by the reference point in the
dynamometer. TheABAQUS
simulation
dynamometer.
The software.
data were obtained
simulation data bywere
the reaction
obtained force
by of
thethe tool reference
reaction force ofpoint in the
the tool ABAQUS
reference software.
point in the ABAQUS
In the verification data, two sets of cutting data were selected, as shown in Figure 12. 12.
software. In the verification data, two sets of cutting data were selected, as shown in Figure Among
Among them,
them,
under under the conditions of feed speed
vf = v f = 4000 mm/min, cutting depth ap = 10 mm, spindle speed
= 10 mm,
ap shown n=
Inthe
theconditions
verification ofdata,
feed speed
two sets of4000
cutting mm/min,
data werecutting depthas
selected, spindle12.
in Figure speed
Among
1500n =r/min
1500 r/min
and and amplitude
amplitude µ = μ =µm,
30 30 μm, Figure
Figure 12a 12a
showsshows the the cutting
cutting widtha aversus
width e versus cutting force
cutting force Fy
them, under the conditions of feed speed vf = 4000 mm/min, cutting depth ape= 10 mm, spindle speed
WithF y With the increase of the cutting width, the experimental value of the rotary-vibration-cutting force
the r/min
increase
n = 1500 andofamplitude
the cutting μ width,
= 30 μm, theFigure
experimental
12a shows value
the of the rotary-vibration-cutting
cutting width ae versus cutting force
component of the disc-cutter increased linearly. This was mainly because the increase of the cutting
component of the disc-cutter increased linearly. This was mainly
Fy With the increase of the cutting width, the experimental value of the rotary-vibration-cutting because the increase of the cutting force
width will increase the contact area between the tool and the workpiece surface. Thus, the cutting
width
component will increase the contactincreased
of the disc-cutter area between the tool
linearly. Thisand wasthemainly
workpiece
becausesurface. Thus, theofcutting
the increase force
the cutting
force increased. Under the conditions of feed speed vf = 4000 mm/min, cutting depth ae = 10 mm,
increased.
width will Under
increase thetheconditions
contact of feed
area speedthe
between vf =tool
4000and mm/min,
the cutting depth
workpiece surface. ae = 10 mm,
Thus, the spindle
cutting
spindle speed n = 1500 r/min and amplitude μ = 30 μm, Figure 12b showed the effect of cutting depth
force n = 1500 r/min
speedincreased. Under and amplitude
theregular
conditions µ = 30 Figure
µm,speed vf 12b showed the effect of cutting e = 10 amm,
adepth p on
ap on cutting force Fy The curve,of feed
with the increase =of4000 mm/min,
the cutting cutting
depth, depthforce
the cutting tends
cutting
spindle speedFbut
force
to increase, ny =The
1500
the regular
r/min curve,
increase and
of the with
entirethe
amplitude μincrease
cutting μm,ofwas
= 30force thealso
Figure cutting
12b depth,
showed
gentler. the effect
the
Because cutting of force
cutting
the disc-cutter tends to
depth
did
aincrease,
p on but
cutting the
force increase
F y The of the
regular entire
curve, cutting
with force
the was
increase also
of gentler.
the cutting
not made the contact area between the tool and the workpiece surface increase during the cutting Because
depth, the disc-cutter
cutting force did not
tends
made
to the contact
increase,
process. but the area between
increase of the
the tool andcutting
entire the workpiece
force was surface increaseBecause
also gentler. during the cutting process.
disc-cutter did
not made the contact area between the tool and the workpiece surface increase during the cutting
process.

(a) Cutting width ae versus cutting force Fy

Figure 12. Cont.

(a) Cutting width ae versus cutting force Fy
Appl. Sci. 2020, 10, 4676 12 of 16
Appl. Sci. 2020, 10, x FOR PEER REVIEW 12 of 16

(b) Cutting depth ap versus cutting force Fy

Figure12.
Figure 12. Simulation
Simulation and
and test
testdata
dataverification.
verification.

Comparing
Comparing theexperiment
the experimentresults
resultswith
with the
the simulation
simulation results,
results,the
theerror
errorisisless
lessthan 13.2%.
than It can
13.2%. It can
bebe verifiedthat
verified thatthe
the finite
finite element
elementmodel
modelproposed
proposed in this paper
in this is basically
paper reasonable.
is basically The toolThe
reasonable. weartool
and the phenolic resin coating outside the Nomex honeycomb-core composite
wear and the phenolic resin coating outside the Nomex honeycomb-core composite material arematerial are neglected
in the simulation
neglected process. The
in the simulation simulation
process. The data are slightly
simulation datasmaller than the
are slightly measured
smaller thandata, but the
the measured
simulation results can be applied to the actual Nomex honeycomb-core composite
data, but the simulation results can be applied to the actual Nomex honeycomb-core composite disc-cutter rotary-
vibration-cutting.
disc-cutter rotary-vibration-cutting.

4. 4. ConstructionofofCutting
Construction CuttingForce
ForcePrediction
Prediction Model
Model Based
Basedon onResponse
ResponseSurface
SurfaceMethod
Method
Based on the verified simulation model of disc-cutter cutting, a three-dimensional cutting force
Based on the verified simulation model of disc-cutter cutting, a three-dimensional cutting force
prediction model of Nomex honeycomb-core material disc-cutter rotating vibration cutting was es-
prediction model of Nomex honeycomb-core material disc-cutter rotating vibration cutting was
tablished by using the response surface method.
established by using the response surface method.
4.1. Design of Cutting Simulation Test Scheme
4.1. Design of Cutting Simulation Test Scheme
In this test, the center complex response surface method is adopted, the cutting depth ap, cutting
In this test, the center complex response surface method is adopted, the cutting depth ap , cutting
width ae and feed speed vf are setting as independent variables and cutting forces Fx, Fy and Fz as
width ae and feed speed vf are setting as independent variables and cutting forces Fx , Fy and Fz as
response values. Each factor in the three-factor center composite design has 5 levels, namely±1 level,
response values. Each factor in the three-factor center composite design has 5 levels, namely±1 level,
0 level and±0.5 level. The coding and level of test factors are shown in Table 4.
0 level and±0.5 level. The coding and level of test factors are shown in Table 4.
Table 4. Test factors and encoding level.
Table 4. Test factors and encoding level.
Encoding Level
Factor
−1 −0.5Encoding
0 Level
0.5 +1
Factor
ap−1(mm) 5−0.5 8.75 12.50 16.25 200.5 +1
ap (mm) ae 5(mm) 58.75 8.75 12.512.5 16.25 20
16.25 20
vf (mm/min) 3000 3750 4500 5250 6000
ae (mm) 5 8.75 12.5 16.25 20

The vNomex
f (mm/min) 3000
honeycomb 3750 rotary-vibration-cutting
core disc-cutter 4500 5250
simulation 6000
test scheme is
shown in Table 5.
The Nomex honeycomb core disc-cutter rotary-vibration-cutting simulation test scheme is shown
in Table 5.
Appl. Sci. 2020, 10, 4676 13 of 16

Table 5. Scheme of cutting simulation center composite design.

Coded Values Actual Values

Sequence
ap (mm) ae (mm) vf (mm/min) ap (mm) ae (mm) vf (mm/min)
1 0.5 0.5 −0.5 16.25 16.25 3750
2 0 0 0 12.5 12.5 4500
3 0 0 1 12.5 12.5 6000
4 0 0 0 12.5 12.5 4500
5 −0.5 0.5 −0.5 8.75 16.25 3750
6 0 0 0 12.5 12.5 4500
7 −0.5 −0.5 0.5 8.75 8.75 5250
8 −1 0 0 5 12.5 4500
9 0 1 0 12.5 20 4500
10 0.5 −0.5 −0.5 16.25 8.75 3750
11 0 0 0 12.5 12.5 4500
12 0 0 −1 12.5 12.5 3000
13 1 0 0 20 12.5 4500
14 0 0 0 12.5 12.5 4500
15 0.5 −0.5 0.5 16.25 8.75 5250
16 −0.5 −0.5 −0.5 8.75 8.75 3750
17 0 −1 0 12.5 5 4500
18 −0.5 0.5 0.5 8.75 16.25 5250
19 0.5 0.5 0.5 16.25 16.25 5250
20 0 0 0 12.5 12.5 4500

4.2. Output Cutting Simulation Results

Based on ABAQUS simulation platform, the simulation test was carried out in accordance with
the cutting simulation center composite design scheme in Table 5, and the simulation test results were
obtained, as shown in Table 6.

Table 6. Test parameters and simulation results of cutting force.

Experimental Combination Response Value

Sequence
ap (mm) ae (mm) vf (mm/min) Fx (N) Fy (N) Fz (N)
1 16.25 16.25 3750 5 7.17 8.31
2 12.5 12.5 4500 4.56 6.49 7.34
3 12.5 12.5 6000 6.01 6.48 7.63
4 12.5 12.5 4500 5.9 6.87 8
5 8.75 16.25 3750 5.92 7.92 9.29
6 12.5 12.5 4500 5.9 6.56 7.67
7 8.75 8.75 5250 4.6 4.96 7.45
8 5 12.5 4500 4.53 6.03 9.03
9 12.5 20 4500 8.67 9.4 10.55
10 16.25 8.75 3750 5.1 5.21 6.25
11 12.5 12.5 4500 5.02 6.68 7.22
12 12.5 12.5 3000 4.21 5.74 6.59
13 20 12.5 4500 6.87 7.2 8
14 12.5 12.5 4500 6.01 6.5 7.74
15 16.25 8.75 5250 5.58 5.3 6.65
16 8.75 8.75 3750 3.95 4 5.65
17 12.5 5 4500 4.03 4.07 6.53
18 8.75 16.25 5250 7.36 9.65 11.32
19 16.25 16.25 5250 9.12 9.2 10.85
20 12.5 12.5 4500 6.1 6.6 7.84
Appl. Sci. 2020, 10, 4676 14 of 16

4.3. Construction of Cutting Force Prediction Model

Based on the experimental design method and response value, combined with the analysis
software Design–Expert, the regression analysis was used to analyze the data. When the regression
equation was established, some items may have no significant effect on the response. In order to obtain
an optimal regression equation, these items should be removed without affecting the accuracy of the
equation. The following equations are quadratic regression models for the rotational vibration cutting
of the Nomex honeycomb-core composite material with disc-cutter.

Fx = +7.215 − 0.153ap − 0.47ae − 1.139 × 10−3 v f + 0.086 × 10−3 ap v f






+0.117 × 10−3 ae v f + 0.012a2e − 0.065 × 10−6 v2f








F y = −5.03 + 0.536ap + 0.253ae + 0.994 × 10−3 v f − 0.014ap ae




(4)

−0.049 × 10−3 ap v f + 0.061 × 10−3 ae v f − 0.077 × 10−6 v2f








Fz = +2.576 − 0.225ae + 1.004 × 10−3 v f − 0.086 × 10−3 ap v f + 0.065 × 10−3 ae v f







+0.015a2p + 0.011a2e



where ap is the cutting depth (mm), ae is the cutting width (mm) and vf is the feed rate (mm/min).

4.4. Variance Analysis

Table 7 is variance analysis of disc-cutter Nomex honeycomb composites ultrasonic
vibration-assisted cutting force prediction model. As can be seen from the results of variance
analysis, in the regression model of Fx and Fy, P < 0.0001 and in regression model of Fz, P = < 0.005,
which indicating that the regression model established for Fx, Fy and Fz was extremely significant.
The feed speed vf , cutting depth ap and cutting width ae had a great influence on the cutting force
of rotary vibration of the disc-cutter. The lack of fit of Fx (P = 0.7098 > 0.05), the lack of fit of
Fy (P = 0.1271 > 0.05) and the lack of fit of Fz (P = 0.0767 > 0.05), indicating that the lack of fit of
regression models of Fx, Fy and Fz was not significant. According to the credibility analysis of the
quadratic regression equation, the coefficient of determination of the regression model of Fx was
R2 = 0.9510 and the adjustment of R2 = 0.9069, indicating that the model could explain 90.69% of the
experimental data; the coefficient of determination of the regression model of Fy was R2 = 0.9568, adjust
R2 = 0.9179, indicating that the model could explain 91.79% of the experimental data; Fz regression
model decision coefficient R2 = 0.8916, adjust R2 = 0.7940, indicating that the model could explain
79.40% of the experimental data.
Combining the above analysis of variance and model significance tests, it is shown that the
predicted values of Fx, Fy and Fz fit well with the experimental values; the regression effect of the
model was great, and it had a high credibility. Therefore, the regression model of the disc-cutter
rotary-vibration-cutting force of the honeycomb-core material established by the response surface
method was effective, and it could be used to analyze and predict the cutting force.
Appl. Sci. 2020, 10, 4676 15 of 16

Table 7. Regression model analysis of variance.

Sources of Sum of Degrees of Mean P

F
Variance Squares Freedom Square (Prob > F)
Model 27.71 9 3.08 21.56 <0.0001
residual 1.43 10 0.14
Loss of quasi 0.53 5 0.11 0.59 0.7098
Fx
Pure error 0.90 5 0.18
Sum 29.14 19
R2 = 0.9510, After the adjustment: R2 = 0.9069
Model 37.66 9 4.18 24.61 <0.0001
residual 1.7 10 0.17
Loss of quasi 1.27 5 0.25 2.99 0.1271
Fy
Pure error 0.43 5 0.085
Sum 39.36 19
R2 = 0.9568, After the adjustment: R2 = 0.9179
Model 32.27 9 3.59 9.14 0.0009
residual 3.92 10 0.39
Loss of quasi 3.14 5 0.63 4.01 0.0767
Fz
Pure error 0.78 5 0.16
Sum 36.19 19
R2 = 0.8916, After the adjustment: R2 = 0.7940

5. Conclusions
In order to improve the processing quality such as surface burrs and cutting damage caused by
the cutting force during rotary-vibration-cutting honeycomb-core material, several key technologies
involved in finite element simulation of honeycomb-core material model were studied in this paper,
following conclusions could be obtained:

(1) The three-dimensional finite element simulation model of disc-cutter which used in
honeycomb-core material ultrasonic vibration-assisted cutting process was established,
the material properties and material failure criteria were studied in detail;
(2) The validation experiment was executed in order to verify the simulation resulted, the relative
error between simulation results and experimental results was less than 13.2%;
(3) The cutting force prediction model was established though the regression analysis based on the
simulation results. According to the cutting force model, the influence of cutting parameters on
cutting force could be predicted; the processing quality and the processing efficiency could be
improved due to cutting parameters regulation;
(4) By analyzing the influence of cutting parameters on the cutting force, it was concluded that larger
cutting depth and smaller cutting width had better cutting performance which was reflected in
less burrs and better surface integrity.

Author Contributions: Conceptualization, writing—original draft, W.C.; funding acquisition, writing—review &
editing, J.Z.; supervision, Y.C. All authors have read and agreed to the published version of the manuscript.
Funding: This work was supported by the Science and Technology Planning Project of Shenzhen Municipality
(JCYJ20180306170733170), National Science and Technology Major Project of the Ministry of Science and Technology
of China (2018ZX04002-001).
Conflicts of Interest: The authors declare no conflicts of interest.
Appl. Sci. 2020, 10, 4676 16 of 16

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