Carbon fiber reinforced plastics (CFRP) are widely used in aerospace applications due to their high specific strength and design flexibility. However, significant subsurface damage often occurs during machining, which severely impacts the service life of the parts. In this paper, the influence of tool parameters and texture parameters on subsurface damage is comprehensively considered, and the Placket-Burman experimental design is used to screen the significance of these factors. Four key parameters that have great influence on the subsurface damage depth are determined: tool Angle, edge shape, texture width, and texture depth. Then, the response surface method is used to establish the prediction model of subsurface damage, and the optimal machining parameters to minimize subsurface damage are determined by combining the white whale optimization algorithm and the genetic algorithm. The experimental results show that the sub-surface damage is reduced by about 50% when using the optimized micro-braided tool compared with the traditional tool. These research results provide new ideas and methods for improving the machining quality of CFRP and optimizing tool parameters.
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