Principle and effectiveness of ice fixation clamping in the milling of GH4099 superalloy honeycomb core

In order to address the existing challenges in the filling clamping methods of metal honeycomb core, such as slow efficiency, difficult post-processing, easy damage to the honeycomb wall, and lack of environmental friendliness, a new method called integral immersion ice fixation clamping for metal honeycomb core was proposed. This study conducted analytical calculations and test analysis on the mechanical properties of superalloy honeycomb core and artificial ice. It elucidated the mechanism of the metal honeycomb core with ice fixation constraint action and verified the effectiveness of ice fixation clamping through cutting tests and finite element simulation methods. The results indicate that introducing the ice fixation clamping method in metal honeycomb core machining provides sufficient support and adhesive strength for the honeycomb wall, reducing the maximum vibration amplitude by approximately 32.77 to 50.57%. When the height of the machined honeycomb core specimen is h ≥ 3 mm, it can prevent axial displacement of the honeycomb wall under the action of cutting force. The ice fixation clamping method improves the ability of the honeycomb core side wall to resist radial deformation and machining stability, and enables the machining quality of the honeycomb core with low damage, and low roughness. This research provides a new method and basic guidance for the reliable clamping of thin-walled porous metal components.