Method for processing glass fiber honeycomb material

Abstract

The embodiment of the application provides a glass fiber honeycomb material processing method, and relates to the technical field of honeycomb composite material processing.The method is characterized in that: rough machining and semi-finishing machining are performed on the thin wall of a part to reserve a uniform machining allowance; the allowance after the semi-finishing machining is divided into a plurality of independent blocks separated from each other through block cutting; and the allowance after the block cutting is finished to a target size.Through the pre-separation of the allowance into independent blocks separated from each other, the stress transmission path between the allowance material and the reserved thin wall is cut off, the cutting force generated in the finishing is limited within a single block and cannot be continuously conducted to the node along the honeycomb wall, thereby preventing the node from being debonded and the thin wall from being missing, and ensuring the forming integrity and profile accuracy of the knife-edge thin wall.

Description

Technical Field

[0001] This invention relates to the field of honeycomb composite material processing technology, and more specifically, to a method for processing glass fiber honeycomb materials. Background Technology

[0002] In related technologies, the processing of fiberglass honeycomb composite materials typically employs conventional milling or ultrasonic cutting methods. Conventional milling uses a combination of cutting tools to cut the honeycomb core, breaking down the material through cutting the honeycomb walls and fragments to remove excess material. Ultrasonic cutting utilizes ultrasonically vibrating dagger-shaped or circular blades to perform insert cutting or layered cutting of the honeycomb material. The effective cutting time in one vibration cycle of the tool is short, and the tool and workpiece are in intermittent contact, which reduces the cutting force.

[0003] However, the cutting force or tearing force perpendicular to the honeycomb wall surface generated when the conventional milling tool contacts the honeycomb wall directly acts on the resin bonding nodes at the intersection of the honeycomb walls. Due to the small bonding area and high resin brittleness, the nodes are prone to failure and detachment first, resulting in the loss of the thin-walled portion that was intended to be retained, forming an irreparable machining defect. Although ultrasonic cutting has a smaller cutting force, existing ultrasonic machining methods still require the tool to continuously cut near the final surface of the part when removing the excess material in the thin-walled area. The tool is in continuous contact with the weak rigid nodes of the honeycomb core, which significantly increases the risk of node fatigue failure and makes it difficult to guarantee the integrity of the thin wall and the surface accuracy. Summary of the Invention

[0004] The present invention aims to provide a method for processing fiberglass honeycomb materials, which can effectively protect the resin bonding nodes at the intersection of the honeycomb walls when processing the knife-edge thin walls of fiberglass honeycomb parts, prevent the nodes from detaching and failing during processing, thereby avoiding the loss of thin wall parts and ensuring the integrity and surface accuracy of the knife-edge thin walls.

[0005] The embodiments of the present invention can be implemented as follows: This invention provides a method for processing fiberglass honeycomb material, used to process fiberglass honeycomb parts, comprising the following steps: S1. Rough and semi-finish machining are performed on the thin-walled parts of the fiberglass honeycomb parts, with uniform machining allowance reserved; S2. The remaining material after semi-finishing is divided into several independent blocks. S3. Perform finishing on the remaining material after segmentation and cutting to process the fiberglass honeycomb parts to the target size.

[0006] In an optional embodiment, in step S2, the remaining material after semi-finishing is cut along a first direction and a second direction, the first direction and the second direction intersecting each other to form a grid-like segmentation.

[0007] In an optional implementation, in step S2, an ultrasonic dagger is used to perform the segmented cutting.

[0008] In an optional implementation, in step S2, a clearance is maintained between the tip of the ultrasonic dagger and the target-sized surface.

[0009] In an optional embodiment, the spacing margin is 0.5~1mm.

[0010] In an optional implementation, in step S2, the size of the independent block formed by the division is 2mm-8mm*2mm-8mm.

[0011] In an optional embodiment, in step S1, the roughing process leaves a allowance of no more than 10 mm; the semi-finishing process uses a honeycomb ball end mill to uniformly cut the allowance to 5-10 mm.

[0012] In an optional implementation, in step S3, a honeycomb shaping tool is used for finishing. After the finishing is completed, the honeycomb shaping tool is reversed and retracted, and a slope angle of 1 to 5° is set away from the target size surface.

[0013] In an optional implementation, the honeycomb shaping cutter is a circular milling cutter.

[0014] In an optional implementation, in step S3, the surface of the target size is a knife-edged thin wall with an edge angle of less than 30° and a thickness that gradually decreases to less than 3 mm.

[0015] The beneficial effects of the fiberglass honeycomb material processing method provided in this embodiment of the invention include: The fiberglass honeycomb material processing method provided in this invention involves first roughing and semi-finishing the thin-walled portion of the part to reserve a uniform processing allowance. Then, the semi-finished allowance is divided into several independent blocks. Finally, the cut-off allowance is finished to the target size. In this process, because the semi-finished allowance is pre-divided into several independent blocks, the stress transmission path within the allowance material and between the allowance and the final retained thin wall is cut off. This allows the tool to remove each independent small block individually during subsequent finishing, confining the cutting force within a single block and preventing continuous transmission and accumulation along the entire honeycomb wall surface. This avoids node fatigue and debonding caused by cutting stress transmission to the resin bonding nodes at the honeycomb wall intersections, solving the problem of thin-walled gaps and improving the forming integrity and surface accuracy of the knife-edge-shaped thin wall. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic flowchart of the fiberglass honeycomb material processing method provided in this embodiment; Figure 2 A schematic diagram of a fiberglass honeycomb structure cut into sections.

[0018] Icons: 1-Honeycomb core; 2-Independent block. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0021] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0022] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0023] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0024] It should be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.

[0025] The following detailed description of the glass fiber honeycomb material processing method provided by the present invention, including its implementation principle and technical effects, is presented in conjunction with the accompanying drawings and examples.

[0026] Please refer to Figure 1 This embodiment provides a method for processing fiberglass honeycomb material, used to process fiberglass honeycomb parts, specifically honeycomb core 1. This embodiment targets fiberglass honeycomb parts that require the formation of knife-edge-shaped thin walls.

[0027] Specifically, the fiberglass honeycomb material processing method provided in this embodiment includes the following steps: S1. Perform roughing and semi-finishing on the thin-walled parts of the fiberglass honeycomb parts, leaving a uniform machining allowance.

[0028] First, the fiberglass honeycomb blank part is held on the worktable of the ultrasonic cutting machine. Rough machining is performed on the thin-walled part to remove most of the material, leaving a rough machining allowance. Then, semi-finishing is performed to distribute the machining allowance evenly throughout the thin-walled area, creating stable allowance conditions for subsequent segmented cutting and finishing.

[0029] The roughing allowance should not exceed 10mm. Semi-finishing is performed using a honeycomb ball end mill, uniformly cutting the allowance to 5-10mm. The spherical cutting surface of the honeycomb ball end mill can be well adapted to the porous structure of the honeycomb core 1, ensuring cutting efficiency while reducing impact on the honeycomb wall nodes. Controlling the allowance within a uniform range of 5-10mm provides sufficient and consistent material thickness for subsequent segmented cutting, while avoiding excessive allowance leading to excessive cutting load during finishing, or insufficient allowance leading to damage to the final profile during segmented cutting.

[0030] Alternatively, in other embodiments, the semi-finishing process can also use other tools with arc-shaped cutting edges instead of the honeycomb ball end mill, as long as the purpose of uniform allowance can be achieved.

[0031] It should be noted that in this embodiment, roughing and semi-finishing are two consecutive machining stages, which can be completed on the same machine tool by switching tools, or they can be completed on different machine tools. This embodiment does not limit this.

[0032] S2. The remaining material after semi-finishing is cut into blocks, dividing the remaining material into several independent blocks 2.

[0033] Please refer to Figure 2After completing step S1, the semi-finished allowance is a uniform thickness layer attached to the knife-edge-shaped thin-walled surface of the part to be formed. In this step, the allowance layer is divided into several independent blocks 2 by segmented cutting.

[0034] Specifically, in this embodiment, the remaining material after semi-finishing is cut along a first direction and a second direction, which intersect to form a grid-like segmentation. The intersection angle of the first and second directions can be determined according to the structural direction of the honeycomb core 1 and the specific shape of the part. For example, when the L direction (the direction of core strip extension) and the W direction (the direction of core unfolding) of the honeycomb core 1 intersect, the first direction can be along the L direction of the honeycomb core 1 and the second direction can be along the W direction of the honeycomb core 1; or the first and second directions can also correspond to the X-axis and Y-axis directions of the part's coordinate system.

[0035] In this embodiment, the first direction and the second direction are perpendicular to each other to form a regular rectangular grid-like division, which facilitates the control of the size consistency of each independent block 2.

[0036] After grid-like segmentation, the dimensions of each independent block 2 formed are 2mm-8mm × 2mm-8mm. Controlling the dimensions of the independent blocks 2 within the above range ensures that the size of each block is small enough so that the cutting force generated by the tool contacting the individual block during finishing is limited to a finite range and will not be transmitted over a large area along the honeycomb wall; it also avoids the block being too small, which would result in excessively long segmentation and cutting processes or the blocks accidentally falling off before finishing.

[0037] It should be noted that the specific dimensions of the independent block 2 can be adjusted according to the specifications of the honeycomb core 1 and the thickness distribution of the knife-edge thin wall. For example, for honeycomb materials with larger core cell sizes, the dimensions of the independent block 2 can be appropriately increased; for areas with extremely thin walls, the dimensions of the independent block 2 can be appropriately decreased.

[0038] Furthermore, in this embodiment, an ultrasonic dagger is used for segmented cutting. The ultrasonic dagger is mounted on an ultrasonic shank and generates high-frequency axial vibration during processing. The high-frequency ultrasonic vibration causes periodic contact and separation between the tool and the honeycomb material during the cutting process, effectively reducing the average cutting force and minimizing the instantaneous impact and fatigue accumulation on the honeycomb wall nodes. This effectively protects the node strength and prevents thin-wall loss during the segmented cutting stage.

[0039] Furthermore, a clearance is maintained between the tip of the ultrasonic dagger and the target-size surface. It is understood that the target-size surface refers to the final profile of the blade-shaped thin-walled structure after machining. The purpose of maintaining this clearance is to prevent the tool from cutting too deeply during segmented cutting, thus damaging the thin-walled body that needs to be preserved.

[0040] In this embodiment, the spacing allowance is 0.5~1mm. It can be understood that the lower limit of 0.5mm ensures basic protection of the final surface, while the upper limit of 1mm avoids excessive spacing allowance that would require the removal of a large amount of material during the finishing stage, thereby ensuring the efficiency and accuracy of the finishing process.

[0041] The core principle of this invention that can effectively prevent thin-wall defects is that: since each independent block 2 has been separated by a slit, the stress transmission path inside the remaining material is cut off, so that the cutting force generated by subsequent finishing is limited to the range of a single block and cannot be continuously transmitted and accumulated along the honeycomb wall to the node.

[0042] S3. Perform finishing on the remaining material after segmentation and cutting to ensure that the fiberglass honeycomb parts are machined to the target size.

[0043] After dividing the allowance into independent blocks 2 in step S2, this step performs finishing on the allowance, removing each independent block 2 one by one, so that the surface of the part reaches the target size.

[0044] Specifically, in this embodiment, a honeycomb molding cutter is used for finishing. The honeycomb molding cutter is a disc milling cutter. The thin-bladed cutting edge of the disc milling cutter can accurately remove material along the honeycomb wall surface, with less compression and pulling effect on the honeycomb structure, which helps to ensure the surface accuracy of the thin wall.

[0045] Furthermore, after finishing, the honeycomb shaping cutter is reversed and retracted, with a ramp angle of 1-5° away from the target size surface. It can be understood that reverse retraction means that after completing the cutting stroke, the honeycomb shaping cutter does not return along the original feed path, but exits the cutting area in the opposite direction to the feed direction.

[0046] During the tool retraction process, a ramp angle of 1-5° is set to allow the tool to gradually move away from the target surface. This ramp angle design gradually reduces the contact force between the tool and the machined surface during retraction, ensuring a smooth separation. This effectively avoids tearing or peeling forces on the already machined thin wall surface caused by direct tool lifting or lateral movement, further reducing the risk of edge chipping and node detachment. The ramp angle is set between 1-5°; the lower limit of 1° ensures a perceptible detachment ramp during retraction, while the upper limit of 5° prevents excessively large ramp angles from causing excessively long retraction strokes and affecting machining efficiency.

[0047] In this embodiment, the surface with the target size is a knife-edge thin wall with an edge angle of less than 30° and a thickness that gradually decreases to less than 3 mm. Specifically, after finishing, the fiberglass honeycomb part is processed to the target size. The surface defined by this target size, that is, the finished surface, is a knife-edge thin wall, characterized by an edge angle of less than 30° and a thickness that gradually decreases to less than 3 mm from the edge inward.

[0048] The beneficial effects of the fiberglass honeycomb material processing method provided in this embodiment of the invention are as follows: The fiberglass honeycomb material processing method provided in this invention involves first roughing and semi-finishing the thin-walled portion of the part to reserve a uniform processing allowance. Then, the semi-finished allowance is divided into several independent blocks 2. Finally, the cut-off allowance is finished to the target size. In this process, because the semi-finished allowance is pre-divided into several independent blocks, the stress transmission path within the allowance material and between the allowance and the final retained thin wall is cut off. This allows the tool to remove each independent small block individually during subsequent finishing, confining the cutting force within a single block and preventing continuous transmission and accumulation along the entire honeycomb wall surface. This avoids node fatigue and debonding caused by cutting stress transmission to the resin bonding nodes at the honeycomb wall intersections, solving the problem of thin-walled gaps and improving the forming integrity and surface accuracy of the knife-edge-shaped thin wall.

[0049] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for processing fiberglass honeycomb material, used for processing fiberglass honeycomb parts, characterized in that, Includes the following steps: S1. Rough and semi-finish machining are performed on the thin-walled parts of the fiberglass honeycomb parts, with uniform machining allowance reserved; S2. The remaining material after semi-finishing is divided into several independent blocks. S3. Perform finishing on the remaining material after segmentation and cutting to process the fiberglass honeycomb parts to the target size.

2. The glass fiber honeycomb processing method of claim 1, wherein, In step S2, the remaining material after semi-finishing is cut along a first direction and a second direction, the first direction and the second direction intersecting each other to form a grid-like segmentation.

3. The method for processing fiberglass honeycomb material according to claim 1, characterized in that, In step S2, an ultrasonic dagger is used to perform the segmented cutting.

4. The method for processing fiberglass honeycomb material according to claim 3, characterized in that, In step S2, a clearance is maintained between the end of the ultrasonic dagger and the target-sized surface.

5. The method for processing fiberglass honeycomb material according to claim 4, characterized in that, The spacing margin is 0.5~1mm.

6. The method for processing fiberglass honeycomb material according to claim 1, characterized in that, In step S2, the dimensions of the independent blocks formed by the division are 2mm-8mm*2mm-8mm.

7. The method for processing fiberglass honeycomb material according to claim 1, characterized in that, In step S1, the roughing process leaves a allowance of no more than 10mm; the semi-finishing process uses a honeycomb ball end mill to uniformly cut the allowance to 5~10mm.

8. The method for processing fiberglass honeycomb material according to claim 1, characterized in that, In step S3, a honeycomb shaping tool is used for finishing. After finishing, the honeycomb shaping tool is reversed and retracted, and a slope angle of 1~5° is set away from the target size surface.

9. The method for processing fiberglass honeycomb material according to claim 8, characterized in that, The honeycomb shaping tool is a circular milling cutter.

10. The method for processing fiberglass honeycomb material according to claim 1, characterized in that, In step S3, the surface of the target size is a knife-edged thin wall with an edge angle of less than 30° and a thickness that gradually decreases to less than 3 mm.

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