Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting Process
Machining Nomex honeycomb composite structures is crucial for manufacturing components that meet stringent industry requirements. However, the complex characteristics of this material require specialized machining techniques to avoid defects, ensure optimal surface quality, and preserve the integrit...
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MDPI AG
2025-06-01
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| Online Access: | https://www.mdpi.com/2075-1702/13/6/515 |
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| author | Oussama Beldi Tarik Zarrouk Ahmed Abbadi Mohammed Nouari Jamal-Eddine Salhi Mohammed Abbadi Mohamed Barboucha |
| author_facet | Oussama Beldi Tarik Zarrouk Ahmed Abbadi Mohammed Nouari Jamal-Eddine Salhi Mohammed Abbadi Mohamed Barboucha |
| author_sort | Oussama Beldi |
| collection | DOAJ |
| description | Machining Nomex honeycomb composite structures is crucial for manufacturing components that meet stringent industry requirements. However, the complex characteristics of this material require specialized machining techniques to avoid defects, ensure optimal surface quality, and preserve the integrity of the cutting tool. Thus, hybrid ultrasonic-vibration-assisted machining (HUSVAM) technology, using a CZ10 combined cutting tool, was introduced to overcome these limitations. To this end, a 3D numerical model based on the finite element method, developed using Abaqus/Explicit 2017 software, allows us to simulate the interaction between the cutting tool and the thin walls of the structure to be machined. The objective of this study was to validate a numerical model through experimental tests while quantifying the impact of critical machining parameters, including the rotation speed and tilt angle, on process performance, in terms of surface finish, tool wear, cutting force components and chip size. The numerical results demonstrated that HUSVAM technology allows for a significant reduction in the cutting force components, with a decrease of between 12% and 35%. Furthermore, this technology improves cutting quality by limiting the deformation and tearing of cell walls, while extending tool life through a significant reduction in wear. These improvements thus contribute to a substantial optimization of the overall efficiency of the machining process. |
| format | Article |
| id | doaj-art-c53f7f3b22e745249c54da12bf75db4d |
| institution | Kabale University |
| issn | 2075-1702 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj-art-c53f7f3b22e745249c54da12bf75db4d2025-08-20T03:27:23ZengMDPI AGMachines2075-17022025-06-0113651510.3390/machines13060515Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting ProcessOussama Beldi0Tarik Zarrouk1Ahmed Abbadi2Mohammed Nouari3Jamal-Eddine Salhi4Mohammed Abbadi5Mohamed Barboucha6Lean Manufacturing et Modélisation Mécanique, Ecole Nationale des Sciences Appliquées, Oujda 60000, MoroccoCentre de Recherche (CREHEIO) de L’Ecole des Hautes Etudes d’Ingénierie, Equipe de Production Intégrée, Oujda 60000, MoroccoLean Manufacturing et Modélisation Mécanique, Ecole Nationale des Sciences Appliquées, Oujda 60000, MoroccoLaboratoire d’Energétique et de Mécanique Théorique et Appliquée, Ecole des Mines de Nancy, Université de Lorraine, F-88100 Saint Dié Des Vosges, FranceDepartment of Pure and Applied Mathematics, Saveetha School of Engineering, SIMATS, Chennai 60210, Tamil Nadu, IndiaLean Manufacturing et Modélisation Mécanique, Ecole Nationale des Sciences Appliquées, Oujda 60000, MoroccoCentre de Recherche (CREHEIO) de L’Ecole des Hautes Etudes d’Ingénierie, Equipe de Production Intégrée, Oujda 60000, MoroccoMachining Nomex honeycomb composite structures is crucial for manufacturing components that meet stringent industry requirements. However, the complex characteristics of this material require specialized machining techniques to avoid defects, ensure optimal surface quality, and preserve the integrity of the cutting tool. Thus, hybrid ultrasonic-vibration-assisted machining (HUSVAM) technology, using a CZ10 combined cutting tool, was introduced to overcome these limitations. To this end, a 3D numerical model based on the finite element method, developed using Abaqus/Explicit 2017 software, allows us to simulate the interaction between the cutting tool and the thin walls of the structure to be machined. The objective of this study was to validate a numerical model through experimental tests while quantifying the impact of critical machining parameters, including the rotation speed and tilt angle, on process performance, in terms of surface finish, tool wear, cutting force components and chip size. The numerical results demonstrated that HUSVAM technology allows for a significant reduction in the cutting force components, with a decrease of between 12% and 35%. Furthermore, this technology improves cutting quality by limiting the deformation and tearing of cell walls, while extending tool life through a significant reduction in wear. These improvements thus contribute to a substantial optimization of the overall efficiency of the machining process.https://www.mdpi.com/2075-1702/13/6/515finite element methodNomex honeycomb structureconventional millingCZ10 toolHUSVAM hybrid machiningtool wear |
| spellingShingle | Oussama Beldi Tarik Zarrouk Ahmed Abbadi Mohammed Nouari Jamal-Eddine Salhi Mohammed Abbadi Mohamed Barboucha Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting Process Machines finite element method Nomex honeycomb structure conventional milling CZ10 tool HUSVAM hybrid machining tool wear |
| title | Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting Process |
| title_full | Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting Process |
| title_fullStr | Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting Process |
| title_full_unstemmed | Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting Process |
| title_short | Optimization of Hybrid Machining of Nomex Honeycomb Structures: Effect of the CZ10 Tool and Ultrasonic Vibrations on the Cutting Process |
| title_sort | optimization of hybrid machining of nomex honeycomb structures effect of the cz10 tool and ultrasonic vibrations on the cutting process |
| topic | finite element method Nomex honeycomb structure conventional milling CZ10 tool HUSVAM hybrid machining tool wear |
| url | https://www.mdpi.com/2075-1702/13/6/515 |
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