Through the energy method proposed in the previous parts of this study, it is possible to predict chip formation and cutting force for a single point tool of arbitrary geometry. By using the predicted results together with an assumption made on the stress distribution on the tool face, the temperature distribution within chip and tool is obtained through a numerical analysis. A characteristic equation of crater wear of carbide tool is derived theoretically and verified experimentally. Computer simulation of crater wear development is then carried out by using the characteristic equation, and the predicted distributions of the stress and the temperature.
A finite element modeling is developed to simulate and visualize the discontinuous chip formation in the orthogonal cutting of 60 percent Cu-40 percent Zn brasses. A ductile fracture criterion expressed as a function of strain, strain rate and hydrostatic pressure is applied to the crack growth from the tool tip to the chip free surface in the segmentation of discontinuous chips. Chip shape and the inclination of fracture surface produced in computational machining are in good agreement with those in actual machining. The visualization of the computational machining processes clarifies the mechanism of discontinuous chip formation. The influences of chip segmentation upon the residual stress and strain in the machined layer are also clarified quantitatively.
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