Modelling of the temperature distribution based on equivalent heat transfer theory and anisotropic characteristics of honeycomb core during milling of aluminum honeycomb core

The honeycomb sandwich structure has been widely used in the field of aerospace owing to extremely high specific strength and specific rigidity. However, the honeycomb core has anisotropic mechanical characteristics and in-plane weak rigidity, which brings new challenges to the cutting process. In this paper, a three-way equivalent heat conduction model including heat conduction and heat convection in the cutting process was established based on the structural characteristics of the honeycomb core. As for the milling cutter combined with the crushing blade and circular blade specified for aluminum honeycomb core, the moving surface heat source of the crushing blade and the moving line heat source of the circular blade during the milling process were proposed. A prediction model of temperature distribution in the milling of aluminum honeycomb core based on the two heat moving sources was established and verified by the milling experiments. Finally, the temperature distribution law and heat affected area of the honeycomb core during the milling process were studied. It was found that the milling temperature of the honeycomb core maintained a high temperature in the contact area, but fell sharply outside the contact area. Moreover, the heat affected area of the milling heat does not exceed three honeycomb cores.