Abstract
Fracture probability of an alumina ceramic tool during the exit of interrupted cutting is calculated using the transient distribution of tool face stresses, which was already obtained through the FEM simulation analysis in the previous paper. Contrary to expectation, the fracture probability reaches the maximum just before the downward crack initiation for making the chip with “foot”. The cutting edge becomes safe immediately after the crack initiation, because the cutting forces drop rapidly and the chip root pushes up the edge flank to yield a hydrostatic stress state. The fracture onset around this instant is proved experimentally. It is also revealed that the edge fracture is restrained by the early initiation of the crack with brittle workpiece and small exit angle, while the fracture is promoted by the delayed initiation with low friction on the tool face.
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