Analysis of influencing factors on the stability of acoustic system for ultrasonic cutting with disc cutter

Nomex honeycomb composite material has a wide range of applications due to its lightweight, high strength, and low-cost advantages. Using ultrasonic-assisted cutting to process it can effectively overcome the shortcomings of traditional high-speed milling. This paper takes the ultrasonic cutting acoustic system of disc cutter as the research object and studies the influence of the cutting force and temperature of the cutter on the stability of the acoustic system utilizing theoretical modeling and experiments, mainly discussing the effect of force load and temperature change on the resonant frequency and amplitude of acoustic system. According to the equation of motion of ultrasonic cutting, the cutting force model of the disc cutter is established, and the theoretical model of temperature with the resonance frequency and amplitude of the ultrasonic cutting acoustic system of the disc cutter is derived. The experiments on the influence of force load and temperature on the stability of the acoustic system are carried out, respectively. The experimental results show that with the increase of cutting force, the resonance frequency of the ultrasonic cutting acoustic system shows an upward trend, and the amplitude shows a downward trend; with the increase in temperature, both resonance frequency and amplitude decrease. In addition, the change in the inclination angle of the disc cutter during machining will also lead to the change in resonance frequency and amplitude of the acoustic system. The experimental results show the cutter’s inclination angle when the machining effect is the best is 6°. This study provides a certain guiding significance for improving the stability of the disc cutter ultrasonic cutting system.