Rotary ultrasonic machining has been approved as an effective and efficient hole making process for carbon fiber–reinforced plastic composites. Hole quality plays an important role in assembling carbon fiber–reinforced plastic components and can be affected by the carbon fiber reinforcement structures. In this study, experiments are conducted to assess hole quality in carbon fiber–reinforced plastic composites with three carbon fiber reinforcement structures under different combinations of machining variables. Hole quality is quantified through geometrical accuracy (perpendicularity, cylindricity, and hole diameter) and surface qualities (delamination and surface roughness). Results show that the highest level of interlacement among yarn of plain woven structure induce the highest level of compression to the workpiece and the largest amount of additional material removal, leading to the largest perpendicularity and hole diameter. The worst fabric integrity of unidirectional structure generates the largest amount of non-uniform material removal on the machined surface, resulting in the largest cylindricity. It is also found that compared with woven structures, unidirectional structure is more likely to induce push-out delamination due to its smaller critical energy release rate. The lowest constancy of the fabric in twill woven structure leads to the largest surface roughness.

旋转超声加工已被批准为碳纤维增强塑料复合材料的有效制孔工艺。孔质量在组装碳纤维增强塑料部件中起着重要作用，并且会受到碳纤维增强结构的影响。在这项研究中，进行了实验，以评估在不同加工变量组合下具有三种碳纤维增强结构的碳纤维增强塑料复合材料的孔质量。孔的质量通过几何精度（垂直度，圆柱度和孔直径）和表面质量（分层和表面粗糙度）来量化。结果表明，在平纹组织纱线中，最高的交织度导致对工件的最高压缩程度和最大的附加材料去除量，从而导致最大的垂直度和孔径。单向结构最差的织物完整性会在机加工表面上产生大量的不均匀材料去除，从而产生最大的圆柱度。还发现，与机织结构相比，单向结构由于其临界能量释放速率较小而更容易引起推出分层。斜纹编织结构中织物的最低恒定性导致最大的表面粗糙度。单向结构最差的织物完整性会在机加工表面上产生大量的不均匀材料去除，从而导致最大的圆柱度。还发现与织造结构相比，单向结构由于其临界能量释放速率较小而更容易引起推出分层。斜纹编织结构中织物的最低恒定性导致最大的表面粗糙度。单向结构最差的织物完整性会在机加工表面上产生大量的不均匀材料去除，从而导致最大的圆柱度。还发现与织造结构相比，单向结构由于其临界能量释放速率较小而更容易引起推出分层。斜纹编织结构中织物的最低恒定性导致最大的表面粗糙度。