A quality and efficiency balanced CFRP cutting strategy: Modeling, analyzing and verification in drilling

Carbon fiber reinforced polymer (CFRP) is difficult to machine due to its unique properties. Improper machining processes can result in various types of damage. The commonly employed method is “small cutting depth with multiple passes”. The hole is drilled with several bits of varying diameters and is enlarged at high speeds and low feeds until the desired diameter is achieved. However, this approach is inefficient as it requires multiple tools for a single hole, which increases both time and costs. To address the trade-off between machining efficiency and quality, this study proposes a multi-edged collaborative cutting strategy. This technique consolidates multiple operations into a single process, achieving a balance between machining quality and efficiency. A case study was conducted using drilling as an example, where a multi-edged cutting drill was designed and tested. Data on axial force, hole diameter variation, burr formation, and subsurface damage were collected and compared with those obtained using a traditional twist drill. The results show that the multi-edged cutting approach significantly reduces the load per cutting edge, alleviates tool wear, and minimizes fluctuations in hole diameter accuracy. Additionally, the sensitivity of machining quality to process parameters is reduced, leading to improved overall performance. This strategy offers a notable advancement in both machining quality and efficiency, effectively resolving the issues traditionally associated with CFRP drilling.