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Chapter 2
2.4 Microcrack formation in the shear zone
2.5 Gross fracture phenomenon ahead of tool-tip
2.6 Workpiece microstructure effect
2.7 Conclusions from the literature review
2.8 Objective and scope of the research
To
address the research gaps identified above and to achieve the main goal of evaluating
size effect due to presence of microcrack, gross fracture and microstructures
during micro-cutting of ductile materials within the framework of FEA and SPH, the following specific
objectives are outlined for this research work:
· To model the microcrack
formation within shear zone during micro-cutting using FEA simulation to
determine the size effect in micro-cutting of ductile materials.
· To evaluate the fracture
energy in micro-cutting using specific work of fracture (R) and J-integral within
framework of fracture mechanics followed by the evaluation of their
contribution in the size effect.
· To model the role of
workpiece microstructure in the size effect during micro-cutting using SPH
simulations.
· To perform orthogonal
micro-cutting experimentation to confirm the micro-cutting process fundamental
characteristics and to validate the FEA and SPH simulations.
· To analyze the effect of various processing parameters such as cutting speed, rake angle, uncut chip thickness and tool edge radius on the size effect in micro-cutting in the presence of microcracks, gross fracture and workpiece microstructure.
2.9 Approach to the work
