Analysis of the cutting force of superalloy honeycomb core with ice fixation

Metal honeycomb core materials have found extensive application in the aerospace industry due to their high specific strength and stiffness. However, the weak in-plane stiffness of these materials makes them susceptible to defects such as burrs, edge collapse, and core deformation during cutting processes. The poor machinability of cutting is a critical factor that limits the wider utilization of metal honeycomb core materials. In order to study the cutting process and its impact on the machining quality of honeycomb cores and tool life, it is essential to investigate the cutting force, which represents a significant physical parameter. In this research, we focused on the ice fixation milling process of GH4099 superalloy honeycomb core as our subject. Taking into account the unique hexagonal structure of the honeycomb core, we analyzed the contact relationship between the milling cutter and the honeycomb core wall. Subsequently, we established a cutting force model to understand the forces at play during the milling process. To validate the accuracy of the cutting force model, we conducted a series of milling experiments. The results showed that the average percentage error in the X direction is below 8.5 %, in the Y direction is below 7.5 %, and in the Z direction is below 7.4 %. Finally, based on the cutting forces, we revealed the formation of typical machining defects in different honeycomb core walls.