Effect of side cutting edge (approach) angle If the side cutting edge angle of a single-point tool is made significantly larger than about 15°, what is the most likely consequence?

Introduction / Context:
The side cutting edge angle (approach angle) influences chip width and thickness, radial/axial force components, and tool edge strength. Choosing it poorly can cause chipping or chatter.

Given Data / Assumptions:

• Turning with a single-point tool on ductile metals.
• Other angles, feeds, and depths of cut are moderate.

Concept / Approach:
Increasing the side cutting edge angle spreads the cut over a wider edge, reducing chip thickness and often improving finish. However, beyond a typical range (about 10–15° for general work), the long, exposed cutting edge becomes weaker, susceptible to chipping at the nose and along the edge, especially under interrupted cuts or hard spots.

Step-by-Step Solution:
As the side cutting edge angle increases, chip thickness reduces and radial force can rise.Edge strength decreases because a longer edge is engaged; localized load at the nose increases risk of micro-chipping.Result: accelerated wear and chipping → reduced tool life.

Verification / Alternative check:
Tool-life tests show that very large approach angles can trigger chatter and edge breakdown, outweighing any finish gain.

Why Other Options Are Wrong:

• “Increases tool life” conflicts with edge-strength considerations at large angles.
• “Slightly decreases but improves finish” can occur at moderate angles, not when it is significantly larger than 15°.
• “Excessive stress regardless of feed” is too absolute; process parameters matter.
• “No effect” is incorrect; approach angle affects force decomposition and chip load.

Common Pitfalls:
Assuming “more angle always better finish” without considering tool strength and chatter limits.

Final Answer:
Produces edge chipping and decreases tool life