Strain-Hardening and Thermal-Softening Effects on Shear Angle Prediction: New Model Development and Validation

The strain-hardening and thermal-softening effects on shear stress and shear angle in orthogonal machining are discussed in this paper. The temperature effect on strain hardening was quantitatively related to the shear angle using Merchant’s upper bound condition to reduce the number of experimentally-obtained coefficients and thus to both reduce cost and increase accuracy in share angle prediction. This quantitative relationship was then integrated with a force based process model and an equal energy type approach in developing a new model. A statistical analysis with experiment data indicated that the new model yielded improved result in accuracy, reliability, insensitivity to nonmodel parameters, and adaptability.