Abstract: Differences between CFRP and Al alloy materials brings great challenges to the process of hybrid composite CFRP/Al. At the same time, the high cost and time consumption of experimental research as well as the rapid development of computer technology, FEM has become a powerful research method for cutting process. The influences of cutting order, feed speed and tool front angle on the cutting force and CFRP damage of 45°fiber Angle UD-CFRP/Al alloy laminates were studied by simplifying the 3D drilling process into the 2D orthogonal cutting macro FEM established with different constitutive models and damage criteria. The simulation results show that the cutting order of CFRP→Al is better than that of Al→CFRP. The effect of feed speed on cutting force and cutting damage is higher than that of tool front angle. When the tool front angle is greater than 5°, feed speed and tool front angle have no significant influence on the cutting force and surface damage of 45°UD-CFRP.