Effect of Designed 3D Reinforcement in Mitigating Machining Damage on CFRP Plates

ABSTRACT Composite materials made of carbon fiber‐reinforced epoxy (CFRP) are widely used in aerospace fields due to their high strength‐to‐weight ratio. However, due to low out‐of‐plane resistance, these materials are often subject to processing damage, such as delamination and matrix cracking, affecting their mechanical properties. The novelty of this paper lies in using a 3D reinforcement to mitigate machining‐induced damage on CFRP, specifically evaluating both compressive strength and surface quality. By comparing tufted and non‐tufted specimens under various machining conditions, the research demonstrates that tufting achieves up to 14% higher compressive strength and a 36% reduction in surface roughness. These mechanical benefits are obtained without a significant increase in material thickness. These findings highlight tufting as a practical and effective 3D reinforcement technique, providing a valuable framework for integrating advanced reinforcement strategies into manufacturing processes for high‐performance composites.