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What are the difficulties in machining phenolic resin Aramid Honeycomb (milling)?
2

What are the difficulties in machining phenolic resin Aramid Honeycomb (milling)?

What are the difficulties in machining phenolic resin Aramid Honeycomb (milling)?

(OP)
What are the difficulties in machining phenolic resin Aramid Honeycomb (milling)?

RE: What are the difficulties in machining phenolic resin Aramid Honeycomb (milling)?

One of the difficulties of machining aramid honeycomb is that it wants to push over away from the cutter,
One but not all methods Is to use cetol alcohol fill the pores then melt the remainder out after machining
There is also a discussion in thread327-304101: Honeycomb core machining
B.R.

You are judged not by what you know, but by what you can do.

RE: What are the difficulties in machining phenolic resin Aramid Honeycomb (milling)?

2
For giggles... in addition to Berkshire's post...

The following documents discuss this issue to greater/lesser extents...

SAE AIR5367 Machining of Composite Materials, Components and Structures

MIL-HDBK-337 Adhesive Bonded Aerospace Structure Repair

MIL-HDBK-349 Manufacture and Inspection of Adhesive Bonded, Aluminum Honeycomb Sandwich Assemblies for Aircraft

MIL-H-87990 [CX] Aluminum Honeycomb Sandwich Assemblies, Manufacture Of


The OBVIOUS KEY is to temporarily stabilize the core during cutting to attain clean deformation-free 'shaping'. This can be done in [2] ways...

Unexpanded core is easiest to machine for 'simple profiles'... since it can be machined on a compressed scale like a solid block of metal or plastic... then be carefully stretched/expanded to full size for installation.

Fully expanded core is flimsy and must be stabilized and cut with extremely sharp/thin/low-drag cutters/blades. Sacrificial face sheets and filler can be used, etc.

NOTES1.
a. Thick/stout core foil in a very small cell shape/size is the absolutely easiest to machine.
b. Thin core foil, in a large cell shape/size is the absolutely hardest to machine... along with honeycomb core that is designed to flex smoothly around curvatures [instead of going anticlastic spastic].
c. Cleaning the individual core-cells of cutting debris and adherent chips is a pain... must be flushed or gently blown-out... and adherent bits taken out with tweezers and Exacto blades.
Regards, Wil Taylor
o Trust - But Verify!
o We believe to be true what we prefer to be true. [Unknown]
o For those who believe, no proof is required; for those who cannot believe, no proof is possible. [variation,Stuart Chase]
o Unfortunately, in science what You 'believe' is irrelevant. ["Orion", Homebuiltairplanes.com forum]

RE: What are the difficulties in machining phenolic resin Aramid Honeycomb (milling)?

(OP)
Thanks for your professional answer, it helped me a lot; thanks. I will carefully read the documents mentioned above

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