The work aims to improve the surface milling quality of the high strength intermediate modulus carbon fiber reinforced plastics (CFRP) by analyzing temperature effects on the surface milling damage evolution. A finite element model, incorporating a moving heat source method, was developed to simulate the thermal-mechanical coupling behavior and temperature field dynamics during CFRP surface milling. The model quantitatively correlated milling temperature variations with fiber-matrix damage across distinct ply orientations (0° and 90°). Numerical results demonstrated that 0° plies experienced the most severe tensile damage, while 90° plies were prone to compressive failure. Experimental validation on CFRP specimens revealed that milling temperatures exceeding 120 °C induce severe surface defects, including burrs, tearing, and delamination. Microstructural analysis further correlated elevated temperatures (> 120 °C) with increased fiber pull-out, resin matrix pits, and progressive delamination at the machined subsurface. The areal extent of these defects expanded with rising temperature, directly compromising surface integrity. These findings emphasized that the critical need to maintain milling temperatures below 120 °C to mitigate thermomechanical damage and improve the machined surface quality of CFRP.
Wang et al. (Sat,) studied this question.