Thermal-induced surface deformation of carbon fiber-reinforced polymer during fiber laser cutting: Finite element modeling and experimental validation

To investigate thermally-induced surface deformation of carbon fiber-reinforced polymer (CFRP) sheets during fiber laser cutting, a combined numerical–experimental approach was employed. A thermo-mechanical finite element model incorporating a homogenized material model and a Gaussian moving heat source was developed to simulate surface deformation behavior. The intrinsic relationships among the laser power, scanning speed and CFRP surface deformation behavior were simulated and analyzed systematically. The results show that surface deformation increases with laser power and decreases with scanning speed, exhibiting nonlinear characteristics. The predicted surface deformation ranged from 0.1185 to 2.2183 mm. The experimental results showed good agreement with the simulations, confirming the reliability of the model. In addition, laser power was found to significantly influence both kerf width and surface deformation. The proposed model provides a practical tool for surface deformation prediction and process parameter optimization in CFRP laser cutting.