Abstract
Thick carbon fiber-reinforced polymer (CFRP) composites are extensively used in aerospace industry, but conventional mechanical drilling often results in burrs, delamination, and significant tool wear. Laser processing introduces heat-affected zones (HAZ) and taper, while pulsed laser trepanning combined with mechanical drilling lacks efficiency for small holes in thick CFRP. This study proposes a high-power laser-mechanical hybrid drilling process, integrating short-duration high-power laser punching with mechanical drilling to reduce defects and tool wear. Experiments on 35mm-thick CFRP laminates explored the effects of laser and mechanical parameters on HAZ morphology, tool temperature, forces, and wear, elucidating material removal mechanisms. The hybrid process effectively controls HAZ size and taper through laser parameter adjustments and reduces tool temperature by 32.4% and cutting forces by 42.4% compared to mechanical drilling. It also minimizes burrs and delamination while reducing tool wear by 38.8% on secondary and 64.66% on primary cutting edges.
