Effect of surface slope of the workpiece on shear angle has been considered by applying Hill’s [1] deformation criteria to the triangular shear zone in orthogonal metal-cutting process with variable undeformed chip thickness. It is shown that the variation of the shear angle with the surface slope δ can be written in the form φ = φ0 + Cδ where “C” is not a constant but depends upon steady state shear angle φ0, surface slope δ, and rake angle α. It is also shown that the present theory is in good agreement with the experimental results of Boothroyd [2].

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