Constitutive flow stress formulation for aeronautic aluminum alloy AA7075-T6 at elevated temperature and model validation using finite element simulation

A judicious material constitutive model used as input to the numerical codes to denote elastic, plastic, and thermomechanical behavior under elevated temperatures and strain rates is essential to analyze and design a process. This work describes the formulation of different constitutive models, such as Johnson–Cook, Zerilli–Armstrong, Arrhenius, and Norton–Hoff models for high-strength aeronautic aluminum alloy AA7075-T6 under a wide range of deformation temperatures and strain rates. The adeptness of the formulated models is evaluated statistically by comparing the value of the correlation coefficient and average absolute error between experimental and predicted flow stress results, and numerically when simulating AA7075-T6 machining process. Though all the models show a reasonable degree of accuracy of fit, based on the average absolute error of the data and finite element predictions when simulating the AA7075-T6 machining process, Zerilli–Armstrong model can offer an accurate and precise estimate and is very close to the experimental results over the other models.