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<p>This study investigates the application of ultrasonic vibration-assisted milling (UVAM) to mitigate heat-induced damage in the machining of Carbon Fiber Reinforced Polymer (CFRP)/aluminum honeycomb sandwich structures. Unlike conventional milling, which causes excessive heat generation through energy-intensive mechanisms like fiber pull-out and plastic deformation, UVAM utilizes high-frequency impact loads to promote material removal via brittle fracture. This process efficiently severs fibers and the fiber-matrix interface, generating fine debris and significantly reducing the heat input. An integrated experimental and numerical methodology was employed, using a finite element model developed in ABAQUS to simulate interfacial heat transfer, validated by comparative milling experiments. The results demonstrate that UVAM achieves a substantial reduction in both thermal and mechanical damage. At a feed rate of 60&#xa0;mm/min, UVAM reduced the temperature transmitted to the aluminum honeycomb core by approximately 29% and core tearing damage by 25%. A further temperature reduction of 31% was observed at a lower feed rate of 40&#xa0;mm/min, confirming that optimized parameters can enhance the process benefits. The study conclusively shows that UVAM is a superior strategy for improving the machining quality and integrity of thermally sensitive composite sandwich structures.</p>

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Analysis of interface temperature transfer of CFRP/aluminum honeycomb sandwich structure during ultrasonic assisted milling

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Shixin Qiu,
  • Bingru Ding,
  • Changwei Jiang,
  • Jianmin Wu,
  • Junli Li,
  • Man Zhao

摘要

This study investigates the application of ultrasonic vibration-assisted milling (UVAM) to mitigate heat-induced damage in the machining of Carbon Fiber Reinforced Polymer (CFRP)/aluminum honeycomb sandwich structures. Unlike conventional milling, which causes excessive heat generation through energy-intensive mechanisms like fiber pull-out and plastic deformation, UVAM utilizes high-frequency impact loads to promote material removal via brittle fracture. This process efficiently severs fibers and the fiber-matrix interface, generating fine debris and significantly reducing the heat input. An integrated experimental and numerical methodology was employed, using a finite element model developed in ABAQUS to simulate interfacial heat transfer, validated by comparative milling experiments. The results demonstrate that UVAM achieves a substantial reduction in both thermal and mechanical damage. At a feed rate of 60 mm/min, UVAM reduced the temperature transmitted to the aluminum honeycomb core by approximately 29% and core tearing damage by 25%. A further temperature reduction of 31% was observed at a lower feed rate of 40 mm/min, confirming that optimized parameters can enhance the process benefits. The study conclusively shows that UVAM is a superior strategy for improving the machining quality and integrity of thermally sensitive composite sandwich structures.