Symmetry-Aware Simulation and Experimental Study of Thin-Wall AA7075 End Milling: From Tooth-Order Force Symmetry to Symmetry-Breaking Dynamic Response and Residual Stress

Symmetry and asymmetry jointly govern the dynamics and surface integrity of thin-wall AA7075 end milling. In this work, a symmetry-aware simulation and experimental framework is developed to connect process parameters with milling forces, dynamic response, surface quality, and through-thickness residual stress. A mechanistic milling-force model is first established for multi-tooth end milling, where the periodically repeated tooth-order excitation provides a nominally symmetric load pattern along the tool path. The predicted forces are then used as input for finite-element modal and harmonic-response analysis of a thin-walled component, revealing how symmetric and anti-symmetric mode shapes interact with the tooth-order excitation to generate locally amplified, asymmetric vibration of the compliant wall. Orthogonal and single-factor milling experiments on AA7075 thin-wall specimens are performed to calibrate and validate the force model, and to quantify the influence of feed per tooth, axial depth of cut, spindle speed, and radial width of cut on deformation, surface roughness, and geometric accuracy. Finally, a thermo-mechanically coupled finite-element model is employed to evaluate the residual-stress field, showing a characteristic pattern in which an initially symmetric thermal–mechanical loading produces depth-wise symmetry breaking between tensile surface layers and compressive subsurface zones. The proposed symmetry-aware framework, which combines milling-force theory, finite-element simulation, and systematic experiments, provides practical guidance for selecting parameter windows that suppress vibration, control residual stress, and improve the machining quality of thin-wall AA7075 components.