碳纤维增经强树脂基复合材料特种加工综述

Carbon fiber reinforced plastic (CFRP) composites exhibit excellent properties such as high specific strength, high specific modulus, good design flexibility and corrosion/fatigue resistance, which endows them with wide applications in aerospace, transportation, wind power and biomedical. However, their anisotropy, non-homogeneity, low interlaminar strength and thermal-sensitive nature pose challenges in its machining. Conventional machining methods encounter problems such as severe tool wear, difficulty in controlling machining surface quality and accuracy, and the tendency to produce delamination, burrs, fiber debonding, and surface cavity. These defects significantly reduce the service performance and reliability of CFRP components. To address these challenges, non-conventional machining methods have been developed and deployed. This paper presents a comprehensive review of four widely applied special machining techniques for CFRP: laser beam machining, electrical discharge machining, water jet machining and ultrasonic vibration machining. The advantages and challenges associated with each technique are detailed, and the mechanisms of defect formation are analyzed, along with defect suppression methods. The review concludes by summarizing the suitable application scenarios for each special machining technique and offers insights into future research directions. Literature review suggests that non-conventional machining shows unique advantages in manufacturing of intricate microstructures, high-precision features and complex shapes. However, its material removal rate is significantly lower than that of traditional machining, limiting its feasibility for large-scale production. Future research should prioritize optimizing non-conventional machining process, hybrid machining process that integrate conventional and non-conventional machining, and development of advanced specialized and intelligent equipment. Additionally, the potential of other non-conventional machining techniques, such as electron beam and ion beam machining, should be actively explored. These studies are crucial for improving the precision and efficiency of advanced composite machining, fostering broader applications of high-performance material.