Force Characteristics and Topography Evolution in End‐Face Grinding of CFRP Circular‐Cell Honeycomb Structures

ABSTRACT Carbon fiber‐reinforced polymer (CFRP) circular‐cell honeycombs are increasingly used in aerospace structures due to their exceptional specific stiffness, yet their low out‐of‐plane rigidity and periodic geometry result in severe force fluctuations and uneven end‐face profile during grinding. This study develops a trajectory‐driven analytical model to predict instantaneous three‐dimensional grinding forces accounting for multi‐point intermittent wheel–cell contact. The model is validated against experimental measurements with good agreement in periodic patterns and amplitude. Time‐domain and spatial correlation analyses reveal inverse coupling between periodic normal force peaks and local material removal, attributed to elastic deformation, matrix densification, and damage accumulation in stiffness‐heterogeneous regions. Parametric sensitivity analysis identifies conditions leading to damage‐dominated removal under aggressive parameters. An optimal process window with moderate depth of cut, feed rate, and spindle speed is established, ensuring stable grinding forces, uniform material removal, and superior surface topography with RMS profile error below 0.018 mm and minimal damage. These findings provide insights into grinding mechanisms and topography characteristics of periodic CFRP honeycomb composites, offering practical guidelines for enhancing surface integrity in polymer composite manufacturing.