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<p>In this paper, a novel laser-assisted helical milling (LAHM) method is proposed to further improve the machining quality of large-diameter holes in carbon fiber–reinforced polymer (CFRP) composites. First, the influence of laser pre-drilling parameters on the heat-affected zone (HAZ) is systematically investigated, and an optimal parameter range is established through comprehensive analysis of exit-side delamination damage. Second, a finite element simulation model—grounded in fracture mechanics theory—is developed to comparatively analyze the deformation and fracture mechanisms of carbon fibers in both LAHM and conventional helical milling (HM). A new methodology is introduced to quantitatively evaluate the stress state within the uncut fiber layer, thereby offering mechanistic insight into fiber fracture behavior and its direct role in damage formation. The carbon fiber removal process is characterized across varying fiber cutting angles, and the underlying mechanism by which LAHM mitigates surface damage is elucidated. Comparative experimental studies are conducted to comprehensively assess and quantify key performance metrics—including cutting forces, temperature evolution, exit delamination extent, and hole surface integrity. The enhanced thermal stability observed during LAHM is attributed to the laser-induced weakening of the fiber–resin interfacial bonding. Experimental results demonstrate that, relative to HM, LAHM reduces the average cutting force, peak cutting temperature, and exit delamination area by 28%, 32%, and 60%, respectively. This improvement stems from a fundamental shift in fiber fracture mode: whereas HM predominantly induces bending- and compression-dominated fiber failure, LAHM promotes shear-dominated fiber fracture. Furthermore, five distinct milling stages—categorized according to tool feed depth—are identified, establishing a systematic framework for understanding the LAHM process kinematics and material removal behavior.</p>

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A Research on Fiber Removal Mechanism and its Effect on Damage Formation of CFRP Composites in Laser-Assisted Helical Milling

  • 期刊论文

  • 发表日期：

    2026年4月15日

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  • Xianjun Kong,
  • Han Cui,
  • Yaodi Wang,
  • Xiaole Liu,
  • Yaohui Zheng,
  • Minghai Wang

摘要

In this paper, a novel laser-assisted helical milling (LAHM) method is proposed to further improve the machining quality of large-diameter holes in carbon fiber–reinforced polymer (CFRP) composites. First, the influence of laser pre-drilling parameters on the heat-affected zone (HAZ) is systematically investigated, and an optimal parameter range is established through comprehensive analysis of exit-side delamination damage. Second, a finite element simulation model—grounded in fracture mechanics theory—is developed to comparatively analyze the deformation and fracture mechanisms of carbon fibers in both LAHM and conventional helical milling (HM). A new methodology is introduced to quantitatively evaluate the stress state within the uncut fiber layer, thereby offering mechanistic insight into fiber fracture behavior and its direct role in damage formation. The carbon fiber removal process is characterized across varying fiber cutting angles, and the underlying mechanism by which LAHM mitigates surface damage is elucidated. Comparative experimental studies are conducted to comprehensively assess and quantify key performance metrics—including cutting forces, temperature evolution, exit delamination extent, and hole surface integrity. The enhanced thermal stability observed during LAHM is attributed to the laser-induced weakening of the fiber–resin interfacial bonding. Experimental results demonstrate that, relative to HM, LAHM reduces the average cutting force, peak cutting temperature, and exit delamination area by 28%, 32%, and 60%, respectively. This improvement stems from a fundamental shift in fiber fracture mode: whereas HM predominantly induces bending- and compression-dominated fiber failure, LAHM promotes shear-dominated fiber fracture. Furthermore, five distinct milling stages—categorized according to tool feed depth—are identified, establishing a systematic framework for understanding the LAHM process kinematics and material removal behavior.