Superalloy honeycomb cores possess excellent properties such as high strength, high stiffness, heat insulation, and vibration isolation, and are widely used in aerospace, and defense industries. Honeycomb materials, due to their thin-walled porous structure, anisotropy, and weak in-plane rigidity, exhibit complex and significant cutting vibration under the intermittent impact of the tool, which differs from traditional thin-walled component machining. The use of ice fixation clamping can reduce vibration amplitude by 50 %. However, there are differences in the cutting responses of honeycomb wall substrates and ice, and cutting vibration remains one of the key issues to be addressed in honeycomb core end milling. Based on kinematic analysis, a mathematical model representing the cutting state between the cutting edge and the honeycomb wall was established, elucidating that the vibration in honeycomb core end milling is a forced vibration under non-harmonic and non-periodic excitations. The main inducing factors of cutting vibration were analyzed, and static and dynamic vibration parameters of the process system were identified based on modal analysis. The end milling experiments of GH4099 superalloy honeycomb core with ice fixation clamping were conducted to clarify the influence of cutting parameters on cutting vibration, and to reveal the mechanism of forced vibration of honeycomb walls under various influencing factors. The research results indicate that the cutting width has the greatest impact on cutting vibration, and the vibration in the feed direction is the most significant. In the high-frequency range of cutting vibration response, there are multiple dominant frequency peaks with large amplitudes, originating from harmonic excitations of the tool system, while the dominant factor in the low-frequency range comes from cutting force excitations. When optimizing vibration reduction processes, priority should be given to keeping the harmonic frequencies of spindle rotation away from the natural frequencies of the tool system, followed by minimizing cutting force excitations as much as possible. Under the processing conditions of this study, using the spindle speed of 7000 r/min, feed rate of 4000 mm/min, cutting depth of 0.5 mm, and cutting width of 0.5 mm can achieve minimal cutting vibration and good surface machining quality of the honeycomb core. This study can provide theoretical support for improving the processing stability and surface machining quality of superalloy honeycomb core materials and can even be applied to the research of the end milling of all thin-walled porous structural components.

中文翻译：

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冰固装夹高温合金蜂窝芯体端铣切削振动特性及机理

高温合金蜂窝芯材具有高强度、高刚度、隔热、隔振等优异性能，广泛应用于航空航天、国防工业等领域。蜂窝材料由于其薄壁多孔结构、各向异性和面内刚性较弱，在刀具的间歇冲击下表现出复杂而显着的切削振动，这与传统的薄壁构件加工不同。采用冰固定夹紧可减少振动幅度50%。然而，蜂窝壁基材和冰的切削响应存在差异，切削振动仍然是蜂窝芯材立铣加工需要解决的关键问题之一。基于运动学分析，建立了切削刃与蜂窝壁之间切削状态的数学模型，阐明了蜂窝芯立铣加工中的振动是非简谐、非周期激励下的受迫振动。分析了切削振动的主要诱发因素，并基于模态分析识别了加工系统的静、动态振动参数。通过冰固定夹紧GH4099高温合金蜂窝芯体立铣实验，阐明切削参数对切削振动的影响，揭示各种影响因素下蜂窝壁受迫振动的机理。研究结果表明，切削宽度对切削振动的影响最大，且进给方向的振动最为显着。在切削振动响应的高频范围内，存在多个振幅较大的主频率峰值，这些主频率峰值源自刀具系统的谐波激​​励，而低频范围内的主导因素来自切削力激励。在优化减振过程时，应优先考虑保持主轴旋转的谐波频率远离刀具系统的固有频率，其次是尽可能减少切削力激励。在本研究的加工条件下，采用主轴转速7000 r/min、进给量4000 mm/min、切削深度0.5 mm、切削宽度0.5 mm，可以实现最小的切削振动和良好的表面加工质量。蜂窝芯。该研究可为提高高温合金蜂窝芯材的加工稳定性和表面加工质量提供理论支撑，甚至可以应用于所有薄壁多孔结构件的立铣研究。