CFRP/metal co-cured structure has been increasingly applied in the aerospace industry due to its outstanding mechanical properties of high specific strength and high stiffness. Compared with the stack structure, the co-cured material of which the metal was heavily wrapped by the CFRP prepregs has better interface performance due to the absence of interface gap, being helpful to improve the bonding strength with other parts. Hole making is an inevitable manufacturing process for the assembly of co-cured material while there still exists several challenges during the drilling operation. To be specific, the hole size with low accuracy and hole morphology with severe defects are the main concerns for the manufacturers, which can be mainly attributed to the tangled chips and high cutting temperatures. To solve the aforementioned problems, the low frequency vibration assisted drilling (LFVAD) operation was performed for the newly developed CFRP/Al co-cured material in the present work. The mechanism and feasibility of controlling the machining defects via LFVAD were theoretically and experimentally explored and the influence of vibration amplitude (VA) on the cutting responses was specially studied. The results show that LFVAD can reduce the average thrust forces and drilling temperatures compared to conventional drilling while the maximum thrust force shows larger magnitude with the elevation of VA, in which the VA of ∼30 μm presents the best one. Meanwhile, LFVAD can on the one hand reduce the scratch traces on the hole wall surface owing to its superior chip breakage effect and thereby improve the drilled hole accuracy, and on the other hand shrink the lower interface damage area due to the reduction of cutting temperatures. The obtained findings of the present work indicate that the proposed LFVAD method presents great superiority for the CFRP/Al co-cured material concerning the machining responses of higher hole accuracy and lower interface damage.

CFRP /金属共固化结构由于其出色的机械特性（高比强度和高刚度）而越来越多地应用于航空航天工业。与叠层结构相比，由于CFRP预浸料的重金属包裹在一起的共固化材料由于没有界面间隙而具有更好的界面性能，有助于提高与其他零件的结合强度。对于共固化材料的组装，打孔是不可避免的制造过程，而在钻孔过程中仍然存在一些挑战。具体来说，低精度的孔尺寸和具有严重缺陷的孔形态是制造商的主要考虑因素，这主要归因于缠结的切屑和较高的切削温度。为了解决上述问题，在本工作中，对新开发的CFRP / Al共固化材料进行了低频振动辅助钻孔（LFVAD）操作。从理论和实验上探讨了通过LFVAD控制加工缺陷的机理和可行性，并专门研究了振动幅度（VA）对切削响应的影响。结果表明，与常规钻井相比，LFVAD可以降低平均推力和钻井温度，而最大推力随VA的升高而增大，其中30μm的VA表现最佳。同时，LFVAD凭借其出色的断屑效果，一方面可以减少孔壁表面的划痕，从而提高钻孔精度，另一方面，由于切削温度的降低，缩小了下部界面损伤区域。从本工作中获得的发现表明，所提出的LFVAD方法对于CFRP / Al共固化材料具有更高的孔精度和更低的界面损伤的加工响应，具有很大的优越性。