Modification of Johnson–Cook Constitutive Parameters in Ball Burnish Simulation of 7075-T651 Aluminum Alloy

The Johnson–Cook model is widely used because of its ability to meet the simulation material requirements in various situations. However, under different working conditions, the accuracy of the model may have errors. In this work, based on Abaqus (Abaqus R2022 Education Edition, Dassault Systèmes, Paris, France) simulation software, Johnson–Cook (JC) constitutive model parameters and compression parameters were selected to simulate the improvement of surface roughness during the ball milling of a 7075-T651 aluminum alloy. In the numerical simulation of ball polishing, the changes in the residual stress field when the Johnson–Cook parameters change are analyzed. By comparing the numerically simulated residual stress fields under the JC parameters calculated at different strain rates, a set of parameters that agrees with the experimental values is selected. The results show that the residual stresses are in line with the experimental values when the strain rate is 10−4s −1. The changes in roughness corresponding to the selected parameters are analyzed. The results indicate that the simulated trend of roughness variation is consistent with the experimental values, and the optimal surface roughness value under a static pressure of 300 N is obtained.