Enhancing Cutting Efficiency and Minimizing Forces for Nomex Honeycomb Core Using Grey Relational Analysis and Desirability Function Analysis
SMALL METHODS(2023)
Abstract
Nomex Honeycomb core is the foundational building block for manufacturing aerospace composite components. Its usage requires machining honeycomb in complex aerodynamic profiles where the quality of the core is governed by accuracy and precision of cut profiles. The assessment of accuracy and precision is directly related to forces induced in the cutting tool and cutting efficiency. These two parameters form the basis of a multi-objective function that this paper aims to optimize for the milling operation. The parameter of depth of cut considered in this paper has not been analyzed in a multi-objective optimization study of the Nomex Honeycomb core previously. A Taguchi-based array of Design of Experiments followed by Analysis of Variance and correlation analysis is utilised. The results indicate that the most significant factor is the feed rate, with a percentage contribution of 72% for the cutting forces and depth of cut, with a percentage contribution of 85% in the case of cutting efficiency. The two parameters are optimized using Desirability Function Analysis and Grey Relational Analysis. The results are validated through experimental runs with an error within 5% of the statistical predictions, with the percentage improvement in cutting forces for optimum runs as compared to the worst experimental run at 47.8%. The percentage improvement in cutting efficiency likewise is 11%. The quality of honeycomb core is governed by the accuracy and precision of cut profiles. The assessment of accuracy and precision is directly delated to the forces induced in the cutting tool and the cutting efficiency. The results of this study indicate that the significant factor is the feed rate with a contribution of 72% for the cutting forces and depth of cut with a contribution of 85% in cutting efficiency.image
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Key words
ANOVA,core machining,damage mechanics simulation,desirability function analysis,grey relational analysis,hashin failure criteria,multi-objective optimization,nomex honeycomb
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