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The experimental results are shown in figure 4. The numerical model assumed a direct transition from the steady crack length to steady-state crack growth with constant Ginit and no plasticity. The crack length was taken as zero at the end of each time step. This was not necessarily a physical assumption because the crack could start at some finite distance from the steady state crack tip. This assumption is reasonable for orthogonal cutting because the experimental results showed that the steady-state crack was initiated at the start of each test. For the crack to propagate, the cohesive zone method was used to calculate the Ginit value for a given crack length. The figure shows that the experimental crack length at the end of each test (dashed lines) matched the numerical model (solid lines).
The general trend of decreasing the Ginit values as the crack length increased is similar for the two cut directions. However, the slope of the fracture process zone was much steeper for the 90 degree cut than for the 45 degree cut. Furthermore, the final steady-state crack length for the 90 degree cut was 50% of that for the 45 degree cut.
Apart from the response to crack initiation and propagation, the effects of the cut direction are also important and have been used to inform design. For example, in design practice, the cut direction is typically aligned with the main stress axis of the material and the cut angle is often less than 45 degrees. In this case, the initial pull off point or the equilibrium point between the lower and upper blade represents the safe crack initiation point. However, this point is not always representative of the initiation condition of the crack. The experimental results presented here are for a cut direction aligned with the material’s main stress axis at cut angles of 45 and 90 degrees. Results in this paper are for the 90 degree cut.
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