Title: Influence of milling parameters on delamination damage of CFRP unidirectional plates

Authors: Yiwei Zhang; Mengke Yan; Guixing Wang; Yang Luo; Tianlong Wen

Addresses: Chongqing Engineering Research Center for Advanced Intelligent Manufacturing Technology, Chongqing Three Gorges University, Chongqing, China; Intelligent Manufacturing Industry Technology Research Institute, Sichuan University of Arts and Science, Dazhou, China; School of Mechatronic Engineering, Southwest Petroleum University, Chengdu, China ' Chongqing Engineering Research Center for Advanced Intelligent Manufacturing Technology, Chongqing Three Gorges University, Chongqing, China ' School of Mechatronic Engineering, Southwest Petroleum University, Chengdu, China; Shanxi Aerospace Tsinghua Equipment Co., Ltd, Changzhi, China ' Intelligent Manufacturing Leading Technology, Chongqing University, Chongqing, China; Engineering Research Centre, Chongqing Three Gorges University, Chongqing, China ' Intelligent Manufacturing Leading Technology, Chongqing University, Chongqing, China; Engineering Research Centre, Chongqing Three Gorges University, Chongqing, China

Abstract: In order to control delamination damage in carbon fibre-reinforced polymer/plastic (CFRP) milling, we analysed the mechanism of delamination damage through experiments with varying fibre cutting angles. A Box-Behnken design was used to simulate delamination damage and establish a prediction model for factors affecting delamination. We found that delamination primarily occurs within a fibre cutting angle range of 45° to 135°, and processing parameters have minimal impact on its distribution. When the fibre direction angle is 0°, minimal damage occurs. The tool helical angle indirectly affects delamination by influencing axial force. Among milling parameters, feed per tooth has the most significant impact on delamination factor, followed by axial cutting depth; spindle speed has minimal effect. To improve processing quality, it is advisable to align tool feed rate with CFRP's fibre direction and use high-speed milling with small feed and shallow cutting depth.

Keywords: CFRP milling; delamination damage; milling parameters; prediction model; machining dynamics.

DOI: 10.1504/IJMMM.2025.147427

International Journal of Machining and Machinability of Materials, 2025 Vol.27 No.2, pp.159 - 178

Received: 26 Jun 2024
Accepted: 11 Oct 2024
Published online: 15 Jul 2025 *

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