Effect of shear angle on chip formation In orthogonal cutting, what is the qualitative effect of a larger shear angle on the shear path length and the resulting chip thickness?

Introduction / Context:
The shear angle is a fundamental variable in chip formation mechanics. It dictates how the material shears along a plane ahead of the tool, thereby controlling chip thickness, cutting force, and heat generation.

Given Data / Assumptions:

• Orthogonal cutting with a sharp tool and continuous chip formation.
• Constant uncut chip thickness and rake angle for reasoning.

Concept / Approach:
A larger shear angle rotates the shear plane closer to the cutting edge, reducing shear plane length. Shorter shear path generally lowers the volume of material undergoing intense shear at once, producing a thinner chip and potentially reducing cutting forces.

Step-by-Step Solution:
Consider geometry: increasing shear angle reduces shear plane length.With the same uncut thickness, chip thickness decreases as shear angle increases (chip ratio improves).Therefore, a large shear angle → short shear path → thin chip.

Verification / Alternative check:
Merchant-type relations link larger positive rake (which tends to increase shear angle) with lower forces and thinner chips, consistent with the qualitative effect described.

Why Other Options Are Wrong:
Options (B), (C), and (D) contradict the geometric implications of increased shear angle; (E) is incorrect because shear angle directly governs chip thickness and path length.

Common Pitfalls:
Confusing the effect of feed (uncut chip thickness) with shear angle; assuming shear angle is fixed independently of tool geometry and friction.

Final Answer:
path of shear is short and chip is thin