Experimental and Numerical Investigation of the Effects of Rotational Speed and Feed Rate on Drilling-Induced Residual Stress in AL2024-T351

Drilling-induced residual stresses can significantly impact the fatigue performance of aluminum alloy components. This paper presents an experimental and numerical study on the impact of rotational speed and feed rate on residual stresses experienced while drilling Al2024-T351 in a dry cutting environment. Drilling experiments were carried out using an 8 mm HSS drill at rotational speeds from 375 to 1250 rpm and feed rates between 0.12 and 0.30 mm/rev. The residual hoop stresses near the hole entrance were measured by surface-mounted strain gauges. For residual stress simulation, a coupled thermo-mechanical finite element model was developed using Abaqus/Explicit. Results showed that increasing rotational speed decreases tensile residual stress, and increasing feed rate greatly increases it. The numerical model reproduces the experimental trends but slightly overpredicts the magnitude of the stress. The findings provide practical guidance for selecting drilling parameters to minimize residual stress in aerospace aluminum alloy component.