Study on the Design of Cutting Disc in Ultrasonic-assisted Machining of Honeycomb Composites

Abstract

To study the influences of geometrical parameters on the design of ultrasonic-assisted cutting disc tool for honeycomb composites, a finite element model integrating the cutting disk and ultrasonic horn was established. The performance of the output amplitude of the cutting disc was analyzed under different geometrical parameters including cutter radius, cutter thickness and anterior angle. Then the influences of the geometrical parameters on the energy density and bending rigidity of the cutting disc were discussed. The simulation results shown that with the increase of cutter radius, both the energy density and rigidity decreased, and the amplitude at the cutting edge increased firstly and then decreased under the interaction of the energy density and rigidity. There was an ideal interval of radius within which the amplitude reached the maximum. With the increase of cutter thickness and anterior angle, the energy density decreased while the rigidity increased, the amplitude at the cutting edge presented a declining trend.