The transition in temperature and associated stress induced during machining, may affect the structural integrity of the Al7075-T6 alloy. In the present study, Steinberg Guinan material parameters were used to investigate the dynamic behaviour viz chip morphology (fracture mechanism), temperature change and flow stress in the elasto-visco material Al7075-T6. An explicit algorithm, was adopted to investigate the outcomes. Results showed chip formation and the mode of fracture was closely related with depth of cut and can influence the temperature and flow stress during the machining process. Work hardening and edge dislocation slip in the secondary shear zone was observed to have a notable influence. An optimal machining condition was found between 0.6 and 0.7 mm depth of cut.

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