Prediction of shear angle for continuous orthogonal cutting using thermo-mechanical constants of work material and cutting conditions

Shear angle is one of the most important parameters in machining. Despite numerous studies devoted to the problem of its theoretical determination, there is no completely analytical way which allows the prediction of this angle using only standard properties the work material and the given cutting conditions, and without any particular coefficients obtained from cutting tests. This study presents a new equation for the determination of the shear angle for continuous cutting assuming the curvilinear form of the shear line. The equation is derived using the experimental data of previous researchers and the theory of plasticity. Experimental verification of the suggested equation for steel and aluminum alloy shows its acceptability for prediction of shear angle in orthogonal continuous cutting.