Study on tearing defects in high-speed milling of aluminium honeycomb core

The tearing defect generated during the processing of aluminium honeycomb core is one of the main factors to reduce the bonding strength between the aluminium honeycomb core and connective face sheet.In order to study the tearing defects formed during high-speed milling of aluminium honeycomb cores, a finite element model for cutting a single honeycomb wall was established.The influence of main processing parameters on tearing defects was explored, and the variation law between tearing defects and cutting forces under different processing parameters was further analysed.The results show that when the entrance angle is in regions I and III, the force F|| parallel to the honeycomb wall is the main reason for the formation of tearing defects.When the entrance angle is in region II, the force F perpendicular to the honeycomb wall has a great influence on the tearing defect.The degree of tearing defects is positively correlated with the force F|| parallel to the honeycomb wall in general, and the influence on tearing defects follows that the entrance angle > feed speed > cutting speed.