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<p>This study investigates the influence of rolling assistance and key cutting parameters on the machining behavior of 7075 aluminum alloy. A coupled thermo-mechanical finite element model was developed in ABAQUS and validated through single-factor cutting experiments. The effects of cutting speed, cutting depth, and rolling depth on three-directional cutting forces, cutting temperature, and residual stress were systematically analyzed. The results show that rolling-assisted cutting significantly reduces cutting resistance compared with conventional cutting, with the average cutting force decreased by approximately 30%. Rolling depth exerts the greatest influence on cutting temperature, while cutting depth dominates the evolution of residual compressive stress, which increased from about 260 to 460&#xa0;MPa under deeper cuts. These findings demonstrate that rolling assistance effectively improves machinability and surface integrity, providing a valuable reference for parameter optimization in the precision machining of aerospace-grade 7075 aluminum alloy.</p>

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Investigation on the Machinability of 7075 Aluminum Alloy Assisted by Rolling

  • 期刊论文

  • 发表日期：

    2025年11月14日

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  • Ping Zhang,
  • Jixin Liu,
  • Songting Zhang

摘要

This study investigates the influence of rolling assistance and key cutting parameters on the machining behavior of 7075 aluminum alloy. A coupled thermo-mechanical finite element model was developed in ABAQUS and validated through single-factor cutting experiments. The effects of cutting speed, cutting depth, and rolling depth on three-directional cutting forces, cutting temperature, and residual stress were systematically analyzed. The results show that rolling-assisted cutting significantly reduces cutting resistance compared with conventional cutting, with the average cutting force decreased by approximately 30%. Rolling depth exerts the greatest influence on cutting temperature, while cutting depth dominates the evolution of residual compressive stress, which increased from about 260 to 460 MPa under deeper cuts. These findings demonstrate that rolling assistance effectively improves machinability and surface integrity, providing a valuable reference for parameter optimization in the precision machining of aerospace-grade 7075 aluminum alloy.