Predictive Tool and Process Design for Efficient Chip Control in Metal Cutting

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This thesis presents the development and validation of a predictive methodology of tool and process design for stable chip breakage in metal cutting. The physics of chip breakage were modeled by a new ductile fracture criterion, which was implemented into a numerical turning simulation model. Additionally, three new models quantify the sensitivities of ductile fracture in the breakage location with respect to the tool and process parameters. A case study showed the high industrial potential of the developed methodology.