Abstract: Based on the motion trajectory equation of a single abrasive grain, this paper uses ABAQUS finite element software to simulate the helical milling process, and analyzes the simulation of the stress distribution at the edge of the hole inlet and outlet and the variation law of milling force. During the process of spiral milling holes in carbon fiber reinforced plastic (CFRP), the variation law of milling force and the influential degree of different process parameters on milling force are studied. Subsequently, an orthogonal experiment for spiral milling was designed, using range analysis to study the experimental results and comparing them with the simulation results to determine the accuracy of the simulation results. The results show that the spindle speed is negatively correlated with the axial milling force, and F_x is minimal at 3 500 r/min. The rotational speed and pitch are positively correlated with the milling force. The revolution speed is the main factor affecting the tangential milling force, while the spindle speed and pitch are the secondary factors. The revolution speed is the main factor affecting the axial milling force, while the pitch and spindle speed are the secondary factors.

Key words: carbon fiber reinforced plastic, helical milling, finite element simulation, orthogonal experiments, milling force