Fibre-pattern-aware machining (FPAM) of carbon fibre-reinforced polymer (CFRP) composites

Geier, Norbert and Bukor, Levente (2026) Fibre-pattern-aware machining (FPAM) of carbon fibre-reinforced polymer (CFRP) composites. In: 4th CIRP Conference on Composite Material Parts Manufacturing, 2026.10.14-16, Olaszország. (In Press)

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Abstract

Fibre orientation has a significant impact on surface generation during the machining of carbon fibre-reinforced polymers (CFRPs), yet it is rarely explicitly incorporated into machining planning. Instead, process optimisation typically treats the laminate as a layered structure and relies on tooling and cutting strategies that mitigate, but do not eliminate, orientation-dependent damage. This paper demonstrates that the explicit detection and exploitation of local fibre-pattern information can significantly improve the quality of machined features. We present a numerical study in which fibre pattern maps of CFRP plates are used to guide a systematic optimisation of hole and groove machining. Results indicate that fibrepattern-aware planning can improve quality by 10.9–51.5% compared to conventional strategies, with the gain primarily dependent on feature size and local fibre-pattern entropy. The findings highlight a practical route to integrate in-plane fibre information into CAM algorithms, offering a cost-effective strategy to reduce machining-induced damage in high-value CFRP manufacturing.

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