Ultrasonic vibration machining (UVM) with a straight blade tool (SBT) is currently an efficient process for part manufacturing of Nomex honeycomb composites (NHCs) in the aerospace industry. To solve the wear evaluation problem of SBT, this study focused on the failure characteristics of tool edge blunting, which was different from that of traditional metal-cutting tools. The edge radius measured by ultra-depth microscope and a dimensionless parameter Bluntness Coefficient () obtained from fiber-cut sharpness test were applied to evaluate SBT wear. The fiber-cut sharpness test was realized by a two-stage model proposed based on fiber failure analysis and force-displacement curve, which were validated by experiments. A standardized testing device was established based on the model, and a relationship between edge radius and was obtained by testing quantitatively blunted SBTs. Machining experiments were carried out to obtain a correlation between tool performance and , and a failure standard of value for SBT was proposed. It was demonstrated that was an efficient indicator for SBT wear evaluation, and the sharpness testing by cutting fibers could characterize SBT wear with favorable accuracy and repeatability.

中文翻译：

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一种用于Nomex蜂窝复合材料加工的直刃刀具磨损测试方法

使用直刃工具 (SBT) 的超声波振动加工 (UVM) 目前是航空航天工业中 Nomex 蜂窝复合材料 (NHC) 零件制造的有效工艺。为了解决SBT的磨损评估问题，本研究重点研究了不同于传统金属切削刀具的刀具刃口钝化的失效特征。采用超深度显微镜测量的边缘半径和光纤切割锐度测试获得的无量纲参数钝度系数（）来评估SBT磨损。基于光纤失效分析和力-位移曲线提出的两阶段模型实现了光纤切割锐度测试，并经过实验验证。基于该模型建立了标准化测试装置，通过定量测试钝化SBT，获得了边缘半径与边缘半径之间的关系。通过加工实验获得了刀具性能与 之间的相关性，并提出了 SBT 的失效标准。事实证明，这是评估SBT磨损的有效指标，并且通过切割纤维进行锐度测试可以表征SBT磨损，具有良好的准确性和可重复性。