Thrust force is the most influential factor to drill-exit damages in the drilling of carbon fiber reinforced polymer/plastic (CFRP). The accurate prediction of the thrust force is important for drilling process optimization to suppress these damages. However, the thrust force is strongly coupled with rapid tool wear, which brings significant challenges to its accurate prediction. This paper proposed a novel mechanical model for predicting thrust force with the consideration of tool wear effects in the drilling of unidirectional CFRP. Firstly, tool wear geometrical characteristics of a twist drill, including rake face, cutting edge and flank face are identified as a line, elliptical arc and line profiles, respectively. The contact conditions and cutting mechanism between CFRP and drill bit are further analyzed based on the identified wear profiles and contact mechanics. Then the thrust forces of the main cutting edge and the chisel edge are modelled based on these analyses. Integrating these forces along the main cutting edges and the chisel edge, the total thrust force in drilling CFRP is predicted considering the tool wear effects. Drilling experiments are carried out to validate the prediction model. The predicted and experimental results are in good agreement.

推力是碳纤维增强聚合物/塑料（CFRP）钻削中钻头出口损坏的最重要因素。推力的准确预测对于优化钻孔过程以抑制这些损害非常重要。然而，推力与快速的工具磨损密切相关，这给其精确的预测带来了巨大的挑战。本文提出了一种新的力学模型，该模型考虑了单向CFRP钻进中的刀具磨损效应，可以预测推力。首先，将麻花钻的刀具磨损几何特征（包括前刀面，切削刃和后刀面）分别识别为直线，椭圆弧和直线轮廓。根据确定的磨损曲线和接触力学，进一步分析CFRP与钻头之间的接触条件和切削机理。然后，基于这些分析，对主切削刃和凿刃的推力建模。将这些力沿主切削刃和凿子边缘整合在一起，可在考虑到刀具磨损影响的情况下预测CFRP钻进时的总推力。进行钻探实验以验证预测模型。预测结果与实验结果吻合良好。进行钻探实验以验证预测模型。预测结果与实验结果吻合良好。进行钻探实验以验证预测模型。预测结果与实验结果吻合良好。