This paper presents an alternative way of producing a hole by using a helical milling concept on a CFRP/Aluminium stacks. Fiber delamination and burr formation which is the main defect occurred during hole making process on CFRP and aluminium were investigate throughout an experimental study. This study focused on the helical milling technique using four types of end mill geometries to produce a hole. Various levels of cutting parameter such as cutting speed, feed rate and depth of cut have been chosen to observe the effect of thrust force, temperature, delamination, burr and surface roughness. The result will be used to determine on which end mill geometry and cutting parameters give the best performance.
