Influence of milling parameters on delamination damage of CFRP unidirectional plates

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.