Abstract
The finite element method is used to investigate the effect of shear plane boundary conditions on the stress field in the workpiece during machining. The balances of force and moment on both the shear plane and the tool rake face are used to calculate the unknown boundary condition, i.e. normal stress distribution on the shear plane. The results of finite element analysis show that the normal stress distribution on the shear plane does not significantly affect the value of the stresses in the workpiece under the tool tip. The length of the shear plane is found to be a major parameter governing the stress field in the workpiece in machining, confirming a previous experimental study.
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