A dynamic and explicit scheme of thermo-elastic-plastic finite element analysis is developed to investigate the phenomena in hyper velocity metal cutting processes. When the cutting speed exceeds the velocity of the plastic waves, a shock wave is generated. Due to the shock wave, high compressive hydrostatic stresses occur ahead of the rake face. High levels of compressive hydrostatic stress may cause brittle fracture of the tool. Hence hyper velocity machining is limited by the velocity of the plastic waves. This fact should be taken into consideration in the design of machine tool and cutting tools for high-speed machining.
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