An extended shear angle model derived from in situ strain measurements during orthogonal cutting

There are numerous cutting models which describe the chip formation process. However, they are based on a number of simplifying assumptions. In order to verify these assumptions and to get a better understanding of the cutting process, the different stress states in the chip formation zone were determined by means of diffraction experiments with monochromatic high-energy synchrotron X-radiation during orthogonal, quasistatic cutting of the material C45E. The results from the experiments are compared with simulated stresses. The experimental data indicate that the assumption of a free chip flow according to the shear angle model of Opitz and Hucks is not valid. The model was therefore extended considering the normal stresses in direction of the chip flow