Experimental and Numerical Study of Milling Tool Wear in Carbon Fiber Reinforced Plastics: Mechanisms and Impact on Machining Quality

ABSTRACT This study combines numerical simulation and experimentation to explore tool wear behavior in Carbon Fiber Reinforced Plastics (CFRP) milling, material removal mechanisms, and the mechanisms of burr formation. A three‐dimensional micro cutting model was established, incorporating the matrix, fiber, and interface, to reveal the intrinsic relationship between tool wear and fiber orientation. The results demonstrate that the model accurately predicts tool wear mechanisms at different fiber orientations, with the most severe wear occurring at a fiber cutting angle of 45°, followed by 0°, 90°, and 135°. Furthermore, the study illuminates the differences in fiber removal mechanisms under varying tool wear profiles, revealing a transition from slight compression and shearing to a pushing‐dominated mechanism as tool wear progresses. Additionally, increased tool wear significantly influences burr formation, with burr characteristics shifting from sparse to dense, eventually leading to tearing and delamination. This research provides new theoretical insights and practical guidance for accurately and timely determining CFRP cutting tool failure and achieving low‐damage machining of CFRP.