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<p>This work develops and validates a coupled thermo-mechanical finite-element method (FEM) to investigate residual stress distribution during friction drilling of AA7075-T651. The model embeds a design-of-experiments (DOE) framework for optimization of operating parameters, rotational speed, feed rate, and thickness. The contributions of such factors to residual stresses were systematically gauged, revealing a significant influence of feed rate and thickness, compared to rotational speed, which shows a trivial influence. The results indicate that, under optimum conditions, friction drilling produces residual compressive stresses near the bushing, gradually converting into tensile stresses far from the hole. Sensitivity analysis reveals a critical influence of fixturing constraints on resulting residual stress profile. Predictions of the model were validated against actual life force and temperature data, and an error margin of around 14.8%, which is reasonable. It initiates a comprehensive framework for predicting and controlling residual stresses during friction drilling, which offers meaningful contributions for manufacturing applications where material integrity becomes a critical issue.</p>

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Analysis and optimization of residual stress in friction drilling of Al7075-T651

  • 期刊论文

  • 发表日期：

    2025年11月18日

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  • Li Shen

摘要

This work develops and validates a coupled thermo-mechanical finite-element method (FEM) to investigate residual stress distribution during friction drilling of AA7075-T651. The model embeds a design-of-experiments (DOE) framework for optimization of operating parameters, rotational speed, feed rate, and thickness. The contributions of such factors to residual stresses were systematically gauged, revealing a significant influence of feed rate and thickness, compared to rotational speed, which shows a trivial influence. The results indicate that, under optimum conditions, friction drilling produces residual compressive stresses near the bushing, gradually converting into tensile stresses far from the hole. Sensitivity analysis reveals a critical influence of fixturing constraints on resulting residual stress profile. Predictions of the model were validated against actual life force and temperature data, and an error margin of around 14.8%, which is reasonable. It initiates a comprehensive framework for predicting and controlling residual stresses during friction drilling, which offers meaningful contributions for manufacturing applications where material integrity becomes a critical issue.