Anyone has experience with machining Airex or Rohacell foams? I've been told by the shop that Rohacell can be CNC milled, with Airex they don't know - so how difficult is it? I need the foam machined to tolerances +/- 0.05 mm, so the question is - is it possible to mill Airex foams to such tolerance, or do I have to triple the budget and go to Rohacell? I don't want angry machinist knocking on my door you know
So I have the 3D solid CAD model of the wing and outer surface model, but the thing is - I want to use Airex C70 core in ~2/3 of the chord, and then last 1/3 is just carbon + aramide layup without any core. The idea is - first 2/3 is as stiff as possible, last 1/3 is elastic to bleed off some air to reduce Cl in high flow speeds.
Now, I need to know exactly how many carbon and aramide layers to use to get the target dislocation, and design transition zone in a way it wil not fail right at the edge of core. How the hell do I approach it? I worked with CalculiX before, but only for some basic laminates. Here I have complex layup and the Airex core, and to be honest I have no idea how to simulate this transition zone, I really need your help