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              Citation: Yongqing Wang, Yongquan Gan, Haibo Liu, Lingsheng Han, Jinyu Wang and Kuo Liu. Surface Quality Improvement in Machining an Aluminum Honeycomb by Ice Fixation. Chinese Journal of Mechanical Engineering. doi: 10.1186/s10033-020-00439-1 shu

              Surface Quality Improvement in Machining an Aluminum Honeycomb by Ice Fixation

              • Author Bio: Yongqing Wang, born in 1969, is currently a professor and a PhD candidate supervisor at Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, China. He received his PhD degree from Dalian University of Technology, China, in 2002. His title is "the Yangtze River scholar Professor"
                Yongquan Gan, born in 1986, is currently a PhD candidate at Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, China. He received his master degree from Dalian Jiaotong University, China, in 2013. His research interest is cryogenic machining
                Haibo Liu, born in 1983, a professor and a PhD candidate supervisor at Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, China. He received his PhD degree from Dalian University of Technology, China, in 2012
                Lingsheng Han, born in 1992, is currently a PhD candidate at Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, China.
                Jinyu Wang, born in 1993, he received his master degree from Dalian University of Technology, China, in 2019
                Kuo Liu, born in 1983, a professor at Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, China. He received his PhD degree from Northeastern University, China, in 2010
              • Corresponding author: Haibo Liu, hbliu@dlut.edu.cn
              • Received Date: 2019-06-27
                Accepted Date: 2019-12-26
                Available Online: 2020-02-28

                Fund Project: National Key Research and Development Program of China 2019YFB2005400Changjiang Scholar Program of Chinese Ministry of Education T2017030Open project of State Key Laboratory of high performance complex manufacturing Kfkt2016-05National Natural Science Foundation of China U1608251

              Figures(10) / Tables(5)

              • A honeycomb structure is widely used in sandwich structure components in aeronautics and astronautics; however, machining is required to reveal some of its features. In honeycomb structures, deficiencies, such as burrs, edge subsiding, and cracking, can easily appear, owing to poor specific stiffness in the radial direction. Some effective fixation methods based on a filling principle have been applied by researchers, including approaches based on wax, polyethylene glycol, iron powder, and (especially) ice. However, few studies have addressed the optimization of the cutting parameters. This study focused on optimizing the cutting parameters to obtain a better surface roughness (calculated as a roughness average or Ra) and surface morphology in the machining of an aluminum alloy honeycomb by an ice fixation method. A Taguchi method and an analysis of variance were used to analyze the effects and contributions of spindle speed, cutting depth, and feed rate. The optimal cutting parameters were determined using the signal-to-noise ratio combined with the surface morphology. An F-value and P-value were calculated for the value of the Ra, according to a "smaller is better" model. Additionally, the optimum cutting parameters for machining the aluminum honeycomb by ice fixation were found at different levels. The results of this study showed that the optimal parameters were a feed rate of 50 mm/min, cutting depth of 1.2 mm, and spindle speed of 4000 r/min. Feed rate was the most significant factor for minimizing Ra and improving the surface morphology, followed by spindle speed. The cutting depth had little effect on Ra and surface morphology. After optimization, the value of Ra could reach 0.218 μm, and no surface morphology deterioration was observed in the verified experiment. Thus, this research proposes optimal parameters based on ice fixation for improving the surface quality.
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