To achieve the required surface characteristics, the experiment and simulation researches on effects of drilling processes on surface quality of aircraft fastener holes drilled on 7075-T7351Al alloy were conducted from the perspective of surface integrity and fatigue life. Compared conventional multi鄄step drilling processes with Winslow, it is found that there are smaller roughness vales (Ra), less operation defects, larger compression residual as well as higher fatigue strength on the machined surfaces produced by multiple鄄step with slow feed (DBM) and Winslow,and
Ra of Winslow is lower than 60%, fatigue limit is 23% higher than that of DBM. Based on test data, two empirical formulas affecting roughness and residual stress are established, and strain distribution and temperature variation are analyzed by numerical simulation. In addition Winslow strengthening mechanism are discussed. It is put forward that appropriate increase in cutting speed or decrease in feed rate can improve surface quality of fastener hole