High efficiency roughing process for the ultrasonic cutting of Nomex honeycomb cores

doi:10.1007/s40436-025-00561-0

Abstract

Abstract: A large amount of work in the ultrasonic cutting of honeycomb cores is concentrated in the roughing stage, but the existing roughing path planning methods cannot achieve high efficiency machining. To solve this problem, this paper proposes a novel method that utilizes a straight blade for overlapping V-shaped cuttings. The proposed method reduces the number of disc cutter cuts by reducing the residual height, thereby significantly reducing the overall machining time. By establishing a cutting efficiency model for the traditional and proposed methods, we demonstrate the high efficiency of the proposed method. Additionally, methods for generating tool pre-processing paths are provided for planar, inclined, and curved parts. By analyzing the machining characteristics of the overlapping V-shaped process, we propose corresponding post-processing schemes. Subsequently, the analysis results of the pre-processing and post-processing were integrated and compiled, and a dedicated processor for honeycomb core roughing-path planning was developed using Matlab. Cutting research on the three roughing processes was conducted using the simulation software Vericut, which further verified the efficiency of the overlapping V-shaped process quantitatively. Finally, by comparing the machining effects of the simulation and experiment, we proved that the honeycomb core roughing processor developed in this study could satisfy actual machining requirements.

The full text can be downloaded at https://doi.org/10.1007/s40436-025-00561-0

Key words: Nomex honeycomb core, Ultrasonic cutting, Straight blade, Roughing path planning, Processor development

Heng Luo, Zhao-Cheng Wei, Zhi-Gang Dong, Ren-Ke Kang, Yi-Dan Wang. High efficiency roughing process for the ultrasonic cutting of Nomex honeycomb cores[J]. Advances in Manufacturing, 2026, 14(2): 377-396.

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