Self-driven micro-vibration cutting strategy and process parameters for CFRP

To overcome challenges in carbon fiber-reinforced polymer (CFRP) machining, including subsurface damage (SSD) control and low machining efficiency, this study introduces a self-driven micro-vibration (SDMV) cutting strategy. By redesigning tool geometry and kinematics, SDMV induces axial inclination and lateral micro-movements of the cutting edge via tool rotation, eliminating the need for external excitation sources. The effects of cutting speed, spindle speed, and cutting depth on cutting force and SSD are evaluated using finite element simulations and experiments. Results show that SDMV cutting reduces cutting force, improves fiber fracture behavior, and minimizes matrix damage. The optimal control of SSD is achieved with a high spindle speed (4000 rpm) and cutting speed (60 mm/min). This work provides an innovative, efficient, and low-damage machining approach for CFRP.