Finishing path planning of Nomex honeycomb core via ultrasonic cutting

Heng Luo; Zhi-Gang Dong; Yan Qin; Ren-Ke Kang; Yi-Dan Wang

doi:10.1007/s40436-025-00583-8

Advances in Manufacturing ›› :1 -19. DOI: 10.1007/s40436-025-00583-8

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Finishing path planning of Nomex honeycomb core via ultrasonic cutting

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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

Heng Luo

Heng Luo is currently a doctoral student in School of Mechanical Engineering, Dalian University of Technology. His research interests include ultrasonic vibration cutting technology and machining technology research.

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-machining materials and precision/ultra-precision processing technologies.

Yan Qin

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

Ren-Ke Kang

Ren-Ke Kang is 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.

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

Ultrasonic cutting is an advanced machining technology applied to Nomex honeycomb cores. However, during the finishing process, machining errors exceeding the allowable tolerances occur owing to the lack of an effective path planning method. This study addresses this issue by examining tool path planning for finishing off various typical honeycomb core features. Initially, a theoretical and experimental comparison of the residual heights of the honeycomb core plane features revealed that machining accuracy was superior along the double-wall direction to that along the perpendicular double-wall direction. Thereafter, the theoretical model of the plane features was used to predict the residual heights of the lead angle in the range of 0°–0.5° along the double-wall direction. In addition, theoretical models for residual height were derived for convex and concave surface features using transverse and longitudinal cutting methods, respectively. This study introduces algorithms for tool interference checking and tool posture adjustment to determine the critical lead angle preventing interference. By integrating these algorithms, a honeycomb core finishing path planning processor was developed on the MATLAB platform. Finally, simulations of the solid model were performed using VERICUT software to verify the feasibility of the proposed algorithms. Actual machining of honeycomb core feature parts demonstrated that the developed finishing processor had the ability to achieve high-precision results.

Keywords

Ultrasonic cutting / Nomex honeycomb core / Finishing / Path planning / Tool posture

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Heng Luo, Zhi-Gang Dong, Yan Qin, Ren-Ke Kang, Yi-Dan Wang. Finishing path planning of Nomex honeycomb core via ultrasonic cutting. Advances in Manufacturing 1-19 DOI:10.1007/s40436-025-00583-8

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