The mechanical state of a surface machined with a tool having flank wear is discussed in this paper, which is the second in a sequence of two papers, the first dealing with sharp tools. A technique is developed to ensure proper contact between artificially produced flank wear land and the workpiece. Mechanical state indices developed earlier, viz., apparent strain energy density, strain hardening index, and residual stress distribution in a semi-infinite model, were found to be governed and characterized by shear plane length, depth of cut, and the flank wear length. Thermal effects due to flank wear were also observed. Depending upon the cutting speed and thus upon the temperature generated, the residual stress pattern is lightly or severely modified. It is established that the thermal effect is primarily the result of yield strength change rather than of thermally induced strain.

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