Determining the shear angle, forces, and sizes of shearing elements during metal cutting

A new solution for the shear angle is proposed which is a generalization of the solution Lee–Shaffer solution and allows the determination of the cutting force and the shearing-element size. Merchant’s experimental data are processed taking into account the resistance force at the cutting edge, and it is shown that accounting for this force leads to the need to increase the internal friction angle in the calculated dependences in order to match theory with experiment. It is shown that the obtained theoretical results agree well with experimental results.