3D FE Cutting Simulations of Nomex Honeycomb Composites in Rotary Ultrasonic Machining Process

In this research a 3D FE rotary ultrasonic cutting simulation model of NHCs core material was developed based on Hashin failure criterion and novel ultrasonic circular saw blade cutter system. Further, 3D FE cutting simulation model was validated by performing RUM experiments on ultrasonic machine tool and explored. Cutting force exhibits inverse relation with vibration amplitude and spindle speed of ultrasonic circular saw blade tool, whereas it shows direct relation with feed rate. Finally, an optimised set of processing parameters was obtained by performing series of cutting simulations and verified by experimental work with a novel ultrasonic circular saw blade cutting tool at resonant frequency of 22,050 Hz, spindle speed 3,000 rpm, feed rate 500 mm/min, cutting width 8 mm, cutting depth 2 mm, and vibration amplitude 25 µm. Moreover, this study provides systematic guideline for RUM process optimisation and improvements of surface quality.