Analysis of friction and cutting parameters when milling honeycomb composite structures

Abstract

In machining, tool/workpiece interface parameters are complicated to estimate by experimental means alone. Numerical methods can then give critical solutions to predict and analyze the parameters influencing the machining. The friction between the tool and the cutter has a direct influence on the milling parameters. Therefore, it is necessary to understand the friction mechanism between the tool and the workpiece to estimate the milling parameters of Nomex honeycomb structures correctly. This work aims to present a 3D Finite Element numerical model allowing the prediction of the cutting forces correctly, the morphology of the chips, and the surface quality generated during the milling of this type of structure. These studies were obtained using the commercial software ABAQUS/Explicit. It has been demonstrated that the coupling between the isotropic elastoplastic approach and the Coulomb friction law can easily simulate the milling of Nomex honeycomb structures and gives excellent results in comparison with those obtained experimentally.