Simulation and Experimental Research on the Longitudinal–Torsional Ultrasonic Cutting Process Characteristics of Aramid Honeycomb Materials

Aiming at the problems of large cutting force, easy honeycomb tearing, and deformation during the traditional cutting process of aramid honeycomb materials and an increase in cutting temperature during continuous processing, which may lead to vibration stoppage, the ultrasonic cutting process characteristics of aramid honeycomb materials were studied. Firstly, torsional vibration was added on the basis of one-dimensional longitudinal ultrasonic vibration cutting (LUC), and the motion characteristics of longitudinal–torsional ultrasonic vibration cutting (LTUC) were analyzed. Secondly, a cutting simulation model was established using finite element simulation software. Under the same cutting parameters, the simulation results for the cutting force and cutting temperature of longitudinal ultrasonic vibration cutting and longitudinal–torsional compound ultrasonic vibration cutting were compared. Then, cutting experiments were conducted to verify the simulation results for cutting force, and single-factor experiments were used to analyze the cutting quality of aramid honeycomb under different processing methods. The results show that the three-directional cutting forces in longitudinal–torsional ultrasonic vibration processing are significantly lower than those in longitudinal ultrasonic vibration processing. The feed force decreased by an average of 28.2%, the tangential force decreased by an average of 45.8%, the axial force decreased by an average of 31.2%, and the tool temperature decreased by 21%. The processing quality of aramid honeycomb using longitudinal–torsional ultrasonic vibration cutting is better than when using longitudinal ultrasonic vibration cutting, which can more effectively reduce cutting stress, cutting force, and tool cutting temperature and show better process characteristics.