玻璃纖維蜂巢複合材料優異之比強度(22.66−78.00 kN∙m/kg)與比剛性(2,111−18,538 kN∙m/kg)，可應用於高負載之機構零件。此外，良好之剪力強度(0.28−4.99 MPa)與剪力模數(0.02−0.99 GPa)，則適用於潰縮結構之被動安全設計。雖然如此，玻璃纖維蜂巢複合材料於實務應用上為一難切削材料。蜂巢結構之幾何不連續及可潰縮特性，常造成切刃與蜂巢結構接觸之幾何變化。當切削型態由剪切轉變為摩擦，促成刀具磨耗加劇、纖維拉出與加工表面產生裂縫。本研究使用超音波振動輔助繞切蜂巢複材，透過氮化鋯鍍層之二水準刀具幾何(直刃與螺旋刃)、三水準之切削速度(30、60與90 m/min)及四水準之振幅(0、6、9與12 μm)，於固定之頻率27 kHz及進給率0.5 mm/rev繞切玻璃纖維蜂窩巢複合材料，預期降低切削力、切削溫度、刀具磨耗與改善加工表面完整性。此外，透過電腦斷層掃瞄觀察材料之內部損傷。研究顯示，相較於傳統加工，直刃刀具於振幅12 μm搭配三水準切削速度，製造之Fx與Fy切削力較傳統加工分別降低~31.53%與37.04%，並產生與傳統相當之切削溫度(~33.3℃)、刀具磨耗(VB 15.7μm)及纖維拉出長度值(~455.4 μm)。此外，當切削速度為30 m/min配合振幅12 μm產生之內部損傷比起無超音波振動輔助降低70.6%。然而於蜂巢節點左側，發現大面積之基底材料損失與裂縫之形成。另一方面，螺旋刃刀具搭配超音波振動輔助繞切，所製造之切削力與材料內部損傷皆劣於傳統加工所製造，並討論與表面完整性之關聯。

Glass fiber honeycomb composite materials have excellent specific strength (22.66−78.00 kN∙m/kg) and specific stiffness (2,111−18,538 kN∙m/kg) for heavy-duty applications whilst their moderate shear strength (0.28−4.99 MPa) and shear modulus (0.02−0.99 GPa) are suitable for crush worth design. However, vibrations and chattering are often exerted in cutting due to their discontinuity on geometric changes and crashworthy characteristics. Hence, the glass fiber honeycomb composite materials are classified to the difficult-to-cut materials.
In this study, experimental evaluations of cutting forces and the degraded machined surface integrity were carried out for the observations of cutting force, cutting temperature, tool wear, machined surface integrity and internal damage in routing of honeycomb composite materials. In the parametric investigation, the effects of the ultrasonic vibration-assisted energy coupling with cutting energy in routing of glass fiber honeycomb composites were studied and analysed, with tool geometry (straight-flute and helical-flute), cutting speeds (30, 60 and 90 m/min) and amplitudes (0, 6, 9 and 12 μm), under a constant frequency of 27 kHz and a feed rate of 0.5 mm/rev. Furthermore, computed tomography (CT) was exhibited to demonstrate the influences of cutting forces to the internal damages in a non-destructive manner.
The results showed reductions of cutting forces, 31.53% and 37.04% for the Fx and Fy respectively, and remaining the same level of cutting temperature by using straight flute router, compared to that in the conventional machining. Similarly, the fiber pull-out lengths of ~455.4 μm and 418.0 μm on the machined double and single walls were respectively reduced, compared to that without using ultrasonic energy. In particular, when the cutting speed is 30 m/min and the amplitude is 12 μm, the internal damage generated is 70.6% lower than that without ultrasonic vibration-assisting energy. However, on the entrance point of the honeycomb node, a large area of loss of matrix material and the formation of cracks were encountered. In the observations of computed tomography, the internal damages in the node points, single and double walls which produced by the helical flute router with ultrasonic vibration-assisted routing, were inferior to those produced by conventional machining. The damages associated with crack width and depth have been presented and reported.

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