Energy-Based Characterization of Drilling-Induced Residual Stresses in AA7075-T6

This study examines the influence of drilling parameters on thrust force, torque, active work, and axial residual stress formation in hot-forged and T6-treated AA7075, a critical high-strength aluminum alloy. A full factorial design was applied using three spindle speeds (800, 1000, 1200 rpm) and three feed rates (0.05, 0.10, 0.15 mm/rev). Cutting force and torque signals were measured using a dynamometer, and axial residual stresses were determined by X-ray diffraction at two locations along the hole depth, namely, the hole entrance (Point A) and the hole exit (Point B). The results show that feed rate is the dominant factor influencing drilling mechanics and residual stress formation, whereas spindle speed mainly affects the thermal and frictional conditions governing stress relaxation. A consistent asymmetry was observed between the two measurement locations, with the exit side exhibiting stronger stress relaxation behavior associated with breakthrough mechanics. Finally, the relationship between active work and axial residual stress is discussed using a qualitative, energy-based interpretation, highlighting active work as a physically meaningful indicator for drilling-induced residual stress evolution.