Coating‐Assisted Stress Regulation for Machining of CFRP and Micro‐Damage Evolution With Different Fiber Orientations

ABSTRACT Carbon fiber reinforced polymers (CFRP) are prone to severe heterogeneous deformation and damage during machining due to their inherent anisotropy, which constrains high‐precision manufacturing. Moreover, the dynamic evolution mechanism of cutting stresses under different fiber orientations remains unclear. So this study focuses on analyzing the dynamic reconstruction mechanism of cutting stress in coated CFRP (CC) and coating‐free CFRP (CFC) across various fiber orientations. Cutting experiments are first performed to analyze the surface quality of CFRP, then a three‐dimensional microscopic finite element model is established, which accurately distinguishes the constitutive behaviors of the fiber, matrix, interface, and epoxy coating; simulation and experimental results of surface damage morphologies at different ply angles were compared. Subsequently, cutting stress distribution and damage depth are further investigated. The results show that the epoxy coating can effectively improve the CFRP machining quality, mitigate matrix failure and brittle fiber fracture, and regulate the cutting stress to reduce the damage depth. This study reveals the physical mechanism of the epoxy coating, realizing the active regulation of CFRP machining through stress reconstruction, and provides novel theoretical insights and methodological support for the optimization of component‐specific CFRP machining with coating control.