Material Removal Mechanism and Damage Behavior in High-speed Milling of High-temperature Alloy Honeycomb Core

doi:10.3901/JME.2022.23.284

Abstract

Abstract: Superalloy honeycomb core material has excellent properties such as high specific stiffness, light weight and good energy absorption characteristics. It is regarded as a potential material for the thermal protection structure of the next generation hypersonic vehicle. High speed milling is an important material reduction manufacturing process in the forming process of Superalloy honeycomb core parts. During high-speed milling of honeycomb core materials, the in-plane stiffness of honeycomb core materials is low and the plasticity of superalloy is good. Small cutting force will produce large plastic deformation of honeycomb wall, resulting in low machining accuracy of honeycomb core and difficult to control machining damage, which will have an adverse impact on subsequent welding, assembly and other processes. Based on the finite element simulation, the material removal mechanism of honeycomb wall cutting is deeply studied, and the effects of milling parameters, tool types and milling methods on milling force and machining damage in the milling process are explored. The results show that the cutting angle of honeycomb wall is the key factor affecting the instantaneous stress distribution and chip forming mechanism in the cutting process of honeycomb core material. For milling parameters, excessive feed rate will lead to machining damage such as core lattice deformation, and reducing the cutting speed will increase the frequency of machining damage such as micro burr; The comparison results of three kinds of cutting tools used here show that the machining quality of vertical milling cutter is the best. Insert Milling will produce obvious axial impact, side milling can effectively avoid axial impact.The effects of milling parameters, tool types and milling methods on machining damage of Superalloy honeycomb core are obtained. The research results provide a theoretical basis and process technology reserve for low damage and high-performance machining of Superalloy honeycomb core.

Key words: honeycomb core, high-temperature alloy, milling, material removal mechanism and machining damage

CLC Number:

TG54

SHI Lanyu, WANG Chenguang, CHEN Jie, GUO Guoqiang, HUANG Wenbin, AN Qinglong, MING Weiwei, CHEN Ming. Material Removal Mechanism and Damage Behavior in High-speed Milling of High-temperature Alloy Honeycomb Core[J]. Journal of Mechanical Engineering, 2022, 58(23): 284-295.

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