Abstract: Carbon Fiber Reinforced Polymer(CFRP) has gained widespread application in the aerospace industry due to its excellent properties such as high specific strength,fatigue resistance,and corrosion resistance.However,the heterogeneity and anisotropy of CFRP make the machining processes more complex compared to traditional metals.CFRP are prone to surface defects,and the high hardness of carbon fibers and carbon fiber powders leads to severe tool wear and low machining efficiency. To address this issue,it focuses on the structure of tool for milling T800-CFRP through comprehensive simulation analysis and milling tests,and analyzes the impact of tool structure on tool life and machining surface quality in terms of tool wear,surface roughness,and burr factors during the milling. Take tool flank wear width (VB),surface roughness (S_a),and burr factor (F_b) as optimization objectives,mapping relationships and a comprehensive evaluation model between these factors and tool parameters such as teeth of tool,rake angle,and clearance angle are established. Subsequently,using a Whale Optimization Algorithm (WOA),the optimal tool structure parameters are determined and validated through test. The results show a reduction of 16.95 % in tool wear,a decrease of 32.41 % in surface roughness,and a reduction of 52.93 % in burr factor.

Key words: T800-CFRP, tool structure optimization, whale optimization algorithm, ABAQUS