Determination of the Shear Angle in the Orthogonal Cutting Process

Determination of the shear angle by experimental and analytical methods, as well as by numerical simulation, is presented. Experimental determination of the shear angle was performed by analyzing the chip roots obtained by the method of cutting process quick stop through purposeful fracture of the workpiece in the area surrounding the primary cutting zone. The analytical determination of the shear angle was carried out using the chip compression ratio and was based on the principle of a potential energy minimum. Measurement of the shear angle in the numerical simulation of orthogonal cutting was performed using the strain rate pattern of the machined material at the selected simulation moment. It was analyzed how the parameters of the Johnson–Cook constitutive equation and the friction model affect the shear angle value. The parameters with a predominant effect on the shear angle were determined. Then the generalized values of these parameters were established with a software algorithm based on identifying the intersection of the constitutive equation parameter sets. The use of generalized parameters provided the largest deviation between experimental and simulated shear angle values from 9% to 18% and between simulated and analytically calculated shear angle values from 7% to 12%.