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<p>Micro-scale machining of carbon fiber-reinforced polymer (CFRP) involves significant challenges including unstable cutting forces, delamination defects, and accelerated tool degradation. This study presents an experimental investigation of a hybrid Cold Air–Minimum Quantity Lubrication (CA-MQL) strategy for micro-milling multi-directional T700 CFRP laminates. Comparative tests under dry and CA-MQL conditions recorded three-component cutting forces, groove-bottom roughness (Ra), delamination factor (Fs) and tool flank wear. Under the tested conditions (nozzle outlet ≈ − 20&#xa0;°C, nozzle angle ≈ 10-15°, lubricant flow 2&#xa0;mL/min), CA-MQL reduced tangential and radial forces: Fx decreased by ≈15.18% and Fy by ≈7.18%, while the axial force Fz showed a modest increase of ≈7.2%. Surface integrity improved under CA-MQL: Ra at the groove bottom decreased by ≈0.2-0.4&#xa0;µm (≈18.3-32.7%) and Fs declined by about 15-20% compared with dry cutting. Tool flank wear was also suppressed (≈30-45% reduction), particularly at higher spindle speeds. To the best of our knowledge, this study provides one of the first systematic experimental evaluations of CA-MQL at micro-milling scale for T700 CFRP. It provides quantitative evidence and mechanistic insights to guide precision hybrid cooling–lubrication strategies.</p>

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Hybrid Cold Air–Minimum Quantity Lubrication Strategy for Micro-milling Multi-directional T700 Carbon Fiber-Reinforced Polymer: Effects on Cutting Forces and Tool Wear

  • 期刊论文

  • 发表日期：

    2026年4月4日

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  • Pengkai Cai,
  • Ziyang Cao,
  • Xin Zhao,
  • Emre Altas,
  • Qiang Wu

摘要

Micro-scale machining of carbon fiber-reinforced polymer (CFRP) involves significant challenges including unstable cutting forces, delamination defects, and accelerated tool degradation. This study presents an experimental investigation of a hybrid Cold Air–Minimum Quantity Lubrication (CA-MQL) strategy for micro-milling multi-directional T700 CFRP laminates. Comparative tests under dry and CA-MQL conditions recorded three-component cutting forces, groove-bottom roughness (Ra), delamination factor (Fs) and tool flank wear. Under the tested conditions (nozzle outlet ≈ − 20 °C, nozzle angle ≈ 10-15°, lubricant flow 2 mL/min), CA-MQL reduced tangential and radial forces: Fx decreased by ≈15.18% and Fy by ≈7.18%, while the axial force Fz showed a modest increase of ≈7.2%. Surface integrity improved under CA-MQL: Ra at the groove bottom decreased by ≈0.2-0.4 µm (≈18.3-32.7%) and Fs declined by about 15-20% compared with dry cutting. Tool flank wear was also suppressed (≈30-45% reduction), particularly at higher spindle speeds. To the best of our knowledge, this study provides one of the first systematic experimental evaluations of CA-MQL at micro-milling scale for T700 CFRP. It provides quantitative evidence and mechanistic insights to guide precision hybrid cooling–lubrication strategies.