Optimizing 5-axis tool positioning and orientation for machining CFRP curved surfaces: considering fibers’ orientation

Carbon fiber-reinforced plastic/polymer (CFRP) is a composite material widely used in industries such as aerospace, medical equipment, and sport products. The angle between the cutting and fiber orientations significantly impacts surface quality during the machining process due to CFRP’s pronounced anisotropy. An acute angle results in a superior surface finish, whereas an obtuse angle can lead to defects. Milling of CFRP curved surfaces necessitates accurate tool position control, given the fiber orientation changes. This paper introduces a novel tool positioning method for machining CFRP curved surfaces, which considers fiber orientation. This strategy ensures an acute angle between the cutting and fiber orientations at any position, thereby enhancing machining quality. Furthermore, a tool position smoothing method is implemented to eliminate machine traces. Simulations and CFRP machining experiments are conducted to demonstrate the strategy’s effectiveness. Microscopic observation and surface roughness tests reveal a 52% reduction in surface roughness of CFRP specimens, with most machining-induced cracks eliminated.