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<p>Nomex honeycomb cores (NHC) are the main materials in sectors such as aeronautics and automotive, thanks to their exceptional mechanical properties, including their lightness and specific rigidity. However, their complex low-density structure poses major challenges in terms of machining, requiring adapted tools and processes. Experimental studies have examined the use of longitudinal ultrasonic vibrations to decrease cutting forces and optimize the process; although, some experimental limitations persist. To overcome these challenges, a three-dimensional numerical model was developed under Abaqus/Explicit version 6.17, integrating longitudinal-torsional ultrasonic vibrations. This model demonstrated a significant reduction in cutting forces, an improvement in the quality of machined surfaces and a limitation of material accumulation, confirming the potential of this approach for machining the NHC structure.</p>

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Optimization of machining of Nomex honeycomb structures by integration of longitudinal-torsional ultrasonic vibrations

  • 期刊论文

  • 发表日期：

    2025年5月10日

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  • Tarik Zarrouk,
  • Mohammed Nouari,
  • Hicham Bouali,
  • Jamal-Eddine Salhi,
  • Ahmed Abbadi,
  • Mohammed Abbadi

摘要

Nomex honeycomb cores (NHC) are the main materials in sectors such as aeronautics and automotive, thanks to their exceptional mechanical properties, including their lightness and specific rigidity. However, their complex low-density structure poses major challenges in terms of machining, requiring adapted tools and processes. Experimental studies have examined the use of longitudinal ultrasonic vibrations to decrease cutting forces and optimize the process; although, some experimental limitations persist. To overcome these challenges, a three-dimensional numerical model was developed under Abaqus/Explicit version 6.17, integrating longitudinal-torsional ultrasonic vibrations. This model demonstrated a significant reduction in cutting forces, an improvement in the quality of machined surfaces and a limitation of material accumulation, confirming the potential of this approach for machining the NHC structure.