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