False Boss Connection for Precision Machining of Composites with Soft and Brittle Characteristics

Abstract

Composite materials are widely used in the new generation of aviation equipment due to their comprehensive performance. However, the part fixture is usually difficult during the machining of composites with soft and brittle characteristics, such as the Nomex honeycomb. Therefore, the holding method based on the false boss connection can be utilized due to its advantages of low cost, less pollution, and a short preparation period. In this study, the method to determine and optimize the critical parameters of the false boss design is proposed to address the issue that they previously relied heavily on the experience of engineers, which often results in much waste of materials. To determine the critical parameters, a simulation model is constructed for Nomex honeycomb core parts machining with a false boss holding. Based on the simulation model, the stability of the machining process is analyzed, and the weak link of the false boss between different milling areas is studied. Furthermore, the difference in the shape of different parts is considered, and the reasonable critical parameters of the false boss are obtained through analysis.