Abstract: This study employed milling and drilling processes to conduct hole-making experiments on Al/AFRP(Aramid fiber reinforced polymer，AFRP) and Al/Carbon fiber reinforced polymer(CFRP) co-cured materials, investigating the impacts of process parameters on hole quality and surface defects, while performing a mechanism analysis in conjunction with cutting forces. By comparing the cutting performances of the two co-cured materials, the study aimed to elucidate the different modes of fiber material fracture and surface formation mechanisms under various processing methods. The results indicated that the axial force during the milling process is more dispersed, which helps to reduce delamination damage and matrix peeling defects in the hole-making process of carbon fiber composites, thereby enhancing chip fragmentation and minimizing wall scratches. This makes milling more suitable for processing Al/CFRP co-cured materials. In contrast, under drilling conditions, the cutting process begins at the drill tip, which concentrates the material removal area and effectively reduces burr accumulation defects in aramid composites, resulting in a 30% improvement in hole quality. Consequently, drilling proves to be more effective for processing Al/AFRP co-cured materials. The research findings demonstrate that at a feed rate of 20 mm/min, the average cutting force for Al/FRP co-cured materials is reduced by 67.25%. Notably, the maximum reduction occurs during the milling of Al/AFRP co-cured materials, reaching 76%. This study reveals the differences in cutting mechanisms for various materials, providing a theoretical foundation for the machining of novel co-cured materials and expanding the application range of composite materials.

Key words: Al/AFRP, Al/CFRP, milling, drilling, cutting force, hole machining quality