Impact of Derivative Cutting on Microtextured Tool Performance in CFRP Machining

Abstract Carbon fiber-reinforced polymer (CFRP) composites are widely used in aerospace and other high-performance fields due to their exceptional properties. However, the heterogeneous nature of CFRP, consisting of fibers, resin matrix, and interfaces, leads to defects such as burrs, tearing, and delamination during machining. Reducing subsurface damage is crucial for extending the lifespan of CFRP components, minimizing repair and maintenance needs, and thus saving costs. Appropriate surface microtexturing has shown potential in reducing subsurface damage in CFRP. However, the microcutting effect of the textures, known as derivative cutting, can increase cutting forces. This article investigates the impact of texture parameters on derivative cutting and its subsequent effect on subsurface damage in CFRP. Finite element modeling elucidates the mechanisms by which microtextured tools interact with CFRP. The findings provide design recommendations for microtextured tools aimed at minimizing subsurface damage in CFRP machining.