Validation of a New Aluminum Honeycomb Constitutive Model for Impact Analyses
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Honeycomb is a structure that consists of two-dimensional regular arrays of open cells. High-density aluminum honeycomb has been used in weapon assemblies to mitigate shock and protect payload because of its excellent crush properties. In order to use honeycomb efficiently and to certify the payload is protected by the honeycomb under various loading conditions, a validated honeycomb crush model is required and the mechanical properties of the honeycombs need to be fully characterized. Volume I of this report documents an experimental study of the crush behavior of high-density honeycombs. Two sets of honeycombs were included in this investigation: commercial grade for initial exploratory experiments, and weapon grade, which satisfied B61 specifications. This investigation also includes developing proper experimental methods for crush characterization, conducting discovery experiments to explore crush behaviors for model improvement, and identifying experimental and material uncertainties.
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Journal of Sound and Vibration
This paper documents the experimental validation of an active control approach for mitigating chatter in milling. To the authors knowledge, this is the first successful hardware demonstration of this approach. This approach is very different from many existing approaches that avoid instabilities by varying process parameters to seek regions of stability or by altering the regenerative process. In this approach, the stability lobes of the machine and tool are actively raised. This allows for machining at spindle speeds that are more representative of those used in existing machine tools. An active control system was implemented using actuators and sensors surrounding a spindle and tool. Due to the complexity of controlling from a stationary co-ordinate system and sensing from a rotating system, a telemetry system was used to transfer structural vibration data from the tool to a control processor. Closed-loop experiments produced up to an order of magnitude improvement in metal removal rate.