Comparative experimental study of ultrasonic cutting para-aramid honeycomb and meta-aramid honeycomb by disc cutter

Wei Xing; Yan Qin; Xiao-Guang Guo; Ming-Ye Wang; Ren-Ke Kang; Zhi-Gang Dong; Yi-Dan Wang

doi:10.1007/s40436-025-00558-9

Advances in Manufacturing ›› : 1 -15. DOI: 10.1007/s40436-025-00558-9

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Comparative experimental study of ultrasonic cutting para-aramid honeycomb and meta-aramid honeycomb by disc cutter

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¹State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology, 116024, Dalian, Liaoning, People’s Republic of China

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^a ydwang@dlut.edu.cn

Wei Xing

Wei Xing is currently a graduate student in School of Mechanical Engineering, Dalian University of Technology. His research interests include ultrasonic cutting technology and high-quality machining processes for low-stiffness materials.

Yan Qin

Yan Qin is a postdoctoral fellow in School of Mechanical Engineering, Dalian University of Technology. Her research interest is 3D scanning measurement technology for discontinuous components.

Xiao-Guang Guo

Xiao-Guang Guo is a professor and doctoral supervisor of School of Mechanical Engineering, Dalian University of Technology. Her research interests are ultra-precision machining theory and technology, molecular dynamics simulation and machining process modeling and simulation, and efficient processing technology for difficult-to-machine materials.

Ming-Ye Wang

Ming-Ye Wang is currently a graduate student in School of Mechanical Engineering, Dalian University of Technology. His research interest is ultrasonic cutting technology.

Ren-Ke Kang

Ren-Ke Kang is a professor and doctoral supervisor of School of Mechanical Engineering, Dalian University of Technology. His main research interests are ultra-precision machining processes and ultra-precision equipment.

Zhi-Gang Dong

Zhi-Gang Dong is a professor and doctoral supervisor of School of Mechanical Engineering, Dalian University of Technology. His main research interests include the high-efficiency machining technology of difficult-to-machine materials and precision/ultra-precision processing technologies.

Yi-Dan Wang

Yi-Dan Wang is a postdoctoral fellow in School of Mechanical Engineering, Dalian University of Technology. His research interests include the theory, key technologies, and equipment for ultrasonic vibration machining of difficult-to-machine materials.

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Abstract

Compared to meta-aramid honeycombs (MAHs), para-aramid honeycombs (PAHs) exhibit superior mechanical and physical properties and can therefore be used in more demanding environments. However, the excellent properties of PAH also bring great challenges to the traditional machining methods, often resulting in terms of large burrs, delamination, tearing, and cell collapse of the honeycomb, as well as severe tool wear problems. These challenges severely limit the application of the PAH. Therefore, investigating effective machining methods for PAH and optimizing the machining quality by determining the influence laws of the process parameters are crucial. In this paper, series of single factor orthogonal experiments were performed to study the effects of machining parameters on ultrasonic cutting characteristics between PAH and MAH in terms of cutting force, cutting temperature and surface quality by disc cutter. Furthermore, this study compared the microscopic ultrasonic cutting processes of PAH and MAH, analyzed the impact of aramid fiber differences on the honeycomb walls fracture process, and revealed the reasons for the differences in experimental results between PAH and MAH. Results proved that PAH exhibited poorer cutting performance compared to MAH: the cutting force and cutting temperature of PAH were both higher than those of MAH, and the machined surface was rougher. The processed surface damage of PAH predominantly manifests as clusters of long uncut fibers, whereas MAH is mostly short burrs. Increasing the ultrasonic amplitude can reduce the cutting forces for PAH and MAH, with a particularly greater reduction in force for PAH. The present study can be used as basis for comprehensive understanding of the differences in the cutting performance and mechanisms of PAH and MAH and optimization of machining parameters for ultrasonic cutting by disc cutter.

Keywords

Para-aramid honeycomb (PAH) / Ultrasonic cutting / Cutting performance / Honeycomb wall cutoff process

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Wei Xing, Yan Qin, Xiao-Guang Guo, Ming-Ye Wang, Ren-Ke Kang, Zhi-Gang Dong, Yi-Dan Wang. Comparative experimental study of ultrasonic cutting para-aramid honeycomb and meta-aramid honeycomb by disc cutter. Advances in Manufacturing 1-15 DOI:10.1007/s40436-025-00558-9

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