Numerical and experimental investigation of the shear angle in high-speed cutting of Al6061-T6

  • Mohan Hao
  • Daochun XuEmail author
  • Pingfa Feng


The shear angle is one of the important factors in cutting deformation and the shear angle theory reveals the relationship between the shear behavior in the primary zone and the tool-chip friction behavior in the secondary zone. In order to deepen the understanding of shear angle theory, the study investigated the shear angle variation in aluminum alloy Al6061-T6 and compared the three conventional shear angle models, Merchant, Lee and Shaffer, and Hucks. To obtain the shear angle more conveniently, a simple approach utilizing the connection between the shear angle and chip thickness was proposed. Orthogonal cutting experiments were conducted on aluminum alloy Al6061-T6. A new cutting simulation model for shear angle and chip thickness of Al6061 with errors below 15% and 10% respectively was proposed in the study. What’s more, it was found that the three shear angle models have their applicable ranges in cutting speed for the aluminum alloy. It is mainly because the internal friction coefficient of workpiece material decreased as cutting speed rose.


High-speed cutting Finite element simulation Aluminum alloy Shear angle Friction angle 


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We thank Melissa Gibbons, PhD, from Liwen Bianji, Edanz Editing China (, for editing the English text of a draft of this manuscript.

Funding information

This work was supported by the National Natural Science Foundation of China (51875045).


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.School of TechnologyBeijing Forestry UniversityBeijingChina
  2. 2.Department of Mechanical EngineeringTsinghua UniversityBeijingChina

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