Deformation prediction of circular cell honeycomb under fixture-workpiece systems

Abstract

Carbon fiber reinforced plastic (CFRP) circular cell honeycombs are increasingly used in lightweight structures, but their weak radial stiffness makes them highly susceptible to deformation during clamping, reducing machining accuracy. Accurately predicting this deformation is essential for improving machining precision and ensuring structural integrity. In this study, a numerical model based on planar beam theory is developed to investigate the deformation mechanism of CFRP circular cell honeycombs. Additionally, a finite element analysis (FEA) model is established to incorporate various clamping factors, providing a more comprehensive prediction framework. Both approaches consider actual workpiece characteristics and clamping conditions. The predicted deformations are quantitatively compared with measured surface profiles, showing that the proposed method achieves a prediction error within 10 %. This validates the accuracy of the approach and confirms its applicability to practical machining conditions. The findings of this study offer valuable guidance for achieving high-precision machining of CFRP circular cell honeycombs, contributing to enhanced machining accuracy and reduced workpiece deformation.