Analysis of cutting performance and chip morphology during longitudinal -torsional ultrasonic milling of aluminum honeycomb structures

Abstract

Aluminum honeycomb structures are widely used in aerospace due to their excellent stiffness-to-weight ratio. However, their thin-walled architecture makes them difficult to machine, leading to deformation, material buildup, tool wear, and surface degradation. This study analyzes ultrasonic vibration-assisted milling of aluminum honeycomb structures by combining 3D numerical modeling and experimental validation. A finite element model using Abaqus/Explicit, based on the Johnson–Cook law, is developed to simulate tool-material interactions and chip formation. A parametric analysis was conducted to evaluate the influence of the vibration mode (longitudinal and longitudinal-torsional), vibration amplitude, feed rate, tool inclination angle, and number of teeth. The results show that ultrasonic vibrations significantly improve machining conditions. The longitudinal-torsional mode reduces cutting forces by 10 to 25%, while increasing the vibration amplitude can lead to a reduction of up to 50% for F x and F y and 55% for F z . Furthermore, vibration assistance promotes chip fragmentation, reduces tool-material contact pressure, limits sticking wear, and decreases cell wall deformation, thus contributing to improved surface quality. These results demonstrate the potential of ultrasonic vibration-assisted milling to optimize the machining of honeycomb structures in demanding industrial applications, particularly in the aerospace field.