Hybrid analytical–numerical solution for the shear angle in orthogonal metal cutting — Part II: experimental verification

The hybrid analytical–finite element model described in Part I is applied to predict the shear angle for a range of cutting velocity, uncut chip thickness, and two tool orthogonal rake angles. Experimental results and an empirical equation are also presented for the influence of the cutting conditions and cutting tool geometry on the chip–tool contact length. It is shown that there is a linear dependence between the chip–tool contact length/uncut chip thickness ratio and chip thickness/uncut chip thickness ratio over the range of cutting conditions assumed. The increase of the shear angle with the tool orthogonal rake is mostly due to the reduction of the specific shear energy in the primary shear zone and the specific friction energy in the secondary shear zone accompanied by a reduction of the chip–tool contact zone. The uncut chip thickness and cutting velocity influence the shear angle through their effect on the interface temperature and hence on the material flow stress in the secondary shear zone. The change in both parameters does not change significantly the specific shear energy in the primary shear zone. The model results are compared with the experimental results for a work material 0.18% C steel. The agreement between the predicted and experimental results is seen to be exceptionally good.