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

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

Open Access
|Jun 2026

Figures & Tables

Figure 1.

The drilling machine setup.

Figure 2.

Al2024-T351 specimens.

Figure 3.

Dimensions of Al2024-T351 plate.

Figure 4.

Geometry and dimensions of the drill bit used in this investigation.

Figure 5.

Mesh generation in drill bit and workpiece.

Figure 6.

Residual stress extraction procedure showing S22 history at gauge-representative elements (Case: Group A, 375 rpm, 0.12 mm/rev).

Figure 7.

Comparison of experimental and Abaqus-predicted residual stress at different spindle speeds for Group A.

Figure 8.

Comparison of experimental and Abaqus-predicted residual stress at different feed rates for Group A.

Material Properties Used for Defining the Al2024-T351 Workpiece in the FE Model_

PropertyValue
Elastic modulus E73 GPa
Poisson’s ratio ν0.33
Yield strength σy369 MPa
Density ρ2770 kg/m3
Thermal conductivity k121W/m·K
Specific heat capacity cp875 J/kg·K
Thermal expansion coefficient α24.7 × 10−6 K−1

Chemical Analysis of Aluminum Alloy 2024-T351_

ElementCuZnMgMnFeSi
According to (EAA)3.8–4.9≤ 0.251.2–1.80.3–0.9≤ 0.5≤ 0.5
Measured4.410.02691.640.4620.280.102
ElementCrTiBiNiAlOthers
According to (EAA)≤ 0.1≤ 0.15------Rem.≤ 0.15
Measured0.00660.0670.00520.0097Rem.0.0229

Johnson-Cook Damage Parameters Used in the Abaqus Material Definition_

ParameterValue
d10.31
d20.045
d3−1.7
d40.005
d50
Melting temperature k775
Transition temperature0
Reference strain rate1
Language: English
Submitted on: Mar 5, 2026
Accepted on: May 11, 2026
Published on: Jun 4, 2026
In partnership with: Paradigm Publishing Services
Publication frequency: 1 issue per year

© 2026 Hareth Amer Mohammed, Abdulhaqq A Hamid, published by ŁUKASIEWICZ RESEARCH NETWORK – INSTITUTE OF AVIATION
This work is licensed under the Creative Commons Attribution 4.0 License.

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