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Ultrasonic cutting technology is widely used in the processing of Nomex honeycomb composites, but the identification of wear state and life prediction of ultrasonic straight-edge cutter are one of the problems to be solved urgently. In this paper, based on the tool wear mechanism, the multi-dimensional parameters of cutting force and cutting sound signal are extracted through experiments, the tool wear characteristics are established, and the tool wear stages are divided based on BP neural network and K-nearest neighbor cluster analysis, we established a tool wear recognition model with an accuracy rate of 92.3%. Further, a remaining life prediction model is established based on the HMM model, which can accurately predict the service life of the tool. The research on the wear state and remaining life of ultrasonic tools in this paper provides theoretical significance for the diagnosis of acoustic system faults and has important engineering value for reducing enterprise economic expenses and improving parts processing quality. [ABSTRACT FROM AUTHOR]

Nomex honeycomb composite material has a wide range of applications due to its lightweight, high strength, and low-cost advantages. Using ultrasonic-assisted cutting to process it can effectively overcome the shortcomings of traditional high-speed milling. This paper takes the ultrasonic cutting acoustic system of disc cutter as the research object and studies the influence of the cutting force and temperature of the cutter on the stability of the acoustic system utilizing theoretical modeling and experiments, mainly discussing the effect of force load and temperature change on the resonant frequency and amplitude of acoustic system. According to the equation of motion of ultrasonic cutting, the cutting force model of the disc cutter is established, and the theoretical model of temperature with the resonance frequency and amplitude of the ultrasonic cutting acoustic system of the disc cutter is derived. The experiments on the influence of force load and temperature on the stability of the acoustic system are carried out, respectively. The experimental results show that with the increase of cutting force, the resonance frequency of the ultrasonic cutting acoustic system shows an upward trend, and the amplitude shows a downward trend; with the increase in temperature, both resonance frequency and amplitude decrease. In addition, the change in the inclination angle of the disc cutter during machining will also lead to the change in resonance frequency and amplitude of the acoustic system. The experimental results show the cutter's inclination angle when the machining effect is the best is 6°. This study provides a certain guiding significance for improving the stability of the disc cutter ultrasonic cutting system. [ABSTRACT FROM AUTHOR]