Abstract: In reference [1], honeycomb material with changing thickness is applied to the molds of radome after it is milled. This paper investigates the stress and strains in the honeycomb material in this process and use these stress and strains as criteria to determine proper portions suitable for milling in one process. These methods avoid the complicated finite modeling process and the errors caused by the finite elements. After proper programming to the FEMAP software, the results in this paper can be displayed in FEMAP in the form of stress and strain level contours, which gives a vivid link between the FEM analysis and the results of this paper.

Key words: changing thickness, honeycomb material, sandwich radome, expanded honeycomb machining, mechanical constrains