Formation of foot occurs in shaping when a cutting tool exits the work piece. It may cause chipping of the cutting edge leaving the exit edge of the work piece. Presence of foot causes difficulties in the manufacture of different assembly. In this experiment, an attempt is made to reduce foot formation of aluminum alloy (4600-M) by beveling the exit edge of the work piece under dry environment. Experimental results are analyzed through ANOVA to find out the significance of machining parameters and exit edge bevel angle to reduce foot formation. It is found out that exit edge bevel angle has more significant effect than cutting velocity and orthogonal rake angle. No foot is observed at 15 ° exit edge bevel angle.

1. IJSRD - International Journal for Scientific Research & Development| Vol. 1, Issue 9, 2013 | ISSN (online): 2321-0613
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Abstract—Formation of foot occurs in shaping when a
cutting tool exits the work piece. It may cause chipping of
the cutting edge leaving the exit edge of the work piece.
Presence of foot causes difficulties in the manufacture of
different assembly. In this experiment, an attempt is made to
reduce foot formation of aluminum alloy (4600-M) by
beveling the exit edge of the work piece under dry
environment. Experimental results are analyzed through
ANOVA to find out the significance of machining
parameters and exit edge bevel angle to reduce foot
formation. It is found out that exit edge bevel angle has
more significant effect than cutting velocity and orthogonal
rake angle. No foot is observed at 15º exit edge bevel angle.
Keywords: Machining; shaping; foot; exit edge; bevel;
ANOVA
I. INTRODUCTION
Occurrence of unwanted foot formation at the exit edge of a
workpiece usually creates problem in a machining
operation. Presence of a foot at the exit edge of a particular
precision component may cause severe problems for
finishing the product and in product assembly. For removing
foot, an additional machining allowance is needed requiring
extra cost. Several researchers reported [1-11] that a part of
workpiece together with chip may be separated from the exit
edge of the workpiece along the tool movement resulting in
a foot; else a burr can be formed attached to the edge.
A number of investigations have been made on this aspect
of machining. Ramraj et al. observed [5] that positive shear
plane changes into the negative shear plane at the tool exit in
the foot formation mechanism, as also reported by
Pekelharing [1]. Hashimura et al. reported [4] that in the
negative burr (break out) stages during the burr
development, foot formation as a part of workpiece is
occurred for brittle materials.
On the other hand, Iwata et al. performed [6] experiments to
understand burr formation mechanism using SEM. Finite
element analysis was also utilized [11-15] to understand the
burr and/or foot formation mechanism to suggest that the
generated crack separates the chip along with some portion
of workpiece at the end of burr formation known as a foot.
Similar observations were also made for different materials
by a group of researchers lead by Das [16, 17]. Shaping burr
and foot formation were explored under different machining
conditions on steels and aluminum alloy and it was found
[18-20] that at an appropriate exit edge bevel, burr as well as
foot formation is suppressed to a large extent. Chern and
Dornfeld introduced [21] a burr or break out model, and
reported the effectiveness of the proposed model to find out
the condition corresponding to suppression of negligible
burr and/or foot formation.
The objective of the present investigation is to explore the
influence of machining conditions and exit edge beveling
made on 4600-M aluminum alloy flats to obtain no foot or
negligible foot formation during orthogonal shaping.
Appropriate exit edge bevel angle of the workpiece is to
evaluate under different machining conditions so that foot
can be reduced significantly or even eliminated.
II. EXPERIMENTAL INVESTIGATION
A. Experimental Details
Experiments have been carried out on Meehanits Metal
Cooper Engineering Limited, India make shaping machine
with brazed HSS tipped sharp new tool for orthogonal
shaping of aluminium alloy (4600-M) flats. To reduce the
possibility of foot formation, cutting velocities, orthogonal
rake angles and exit edge bevel angles of the specimen have
been varied. Dry environment is maintained, and depth of
cut is kept constant at 0.05 mm. Details of the experimental
set up and machining conditions are shown in Table 1. Six
tests are carried out at six different exit edge bevel angles of
0o
, 15o
, 20o
, 25o
, 30o
, and 35o
. Experiment set 3 and 4 are
performed as repeat tests to check repeatability. Quantitative
amount of foot at the exit edge is assessed under a tool
maker’s microscope and the observed foot is classified in 10
point scale as detailed in Table 2. Results obtained from the
experiment are utilized for regression analysis, and
regression equation is evaluated using ANOVA.
Experimental results and that evaluated through regression
analysis are also compared.
Machine
Tool
Shaping machine, Meehanits Metal Cooper
Engineering Limited, Satara, India. Main
motor power: 10 HP
Cutting
Tool
Brazed HSS tipped broad nose tool
Style of Tool: ISO 7 L.H
Tool
Geometry
Orthogonal clearance angle: 3°, Inclination
angle: 0o
,
Orthogonal rake angle: -3°, 0° and 5°
Workpiece
Material
Aluminium alloy (4600-M), hardness : 170
BHN
Composition: Si (10.86%), Cu (0.065%),
Mg (0.048%),
Mn (0.32%), Ni (0.05%), Zn (0.072%), Pb
(0.062%),
Sn (0.035%), Ti (0.083%), Fe (0.56%)
Machining
Condition
Type of machining: Orthogonal machining,
environment: Dry
Cutting velocity: 10, 15 and 22 m/min
Depth of cut (t): 0.05 mm, width of cut: 2.5
mm
Table. 1: Experimental Set Up and Machining Conditions
Experimental Observation on Reduction of Foot Formation of 4600-M
Aluminum Alloy in Shaping
P. P. Saha1
Santanu Das2
1, 2
Department of Mechanical Engineering
1, 2
Kalyani Government Engineering College, Kalyani, Nadia, West Bengal, India

2. Experimental Observation on Reduction of Foot Formation of 4600-M Aluminum Alloy in Shaping
(IJSRD/Vol. 1/Issue 9/2013/0068)
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Scale
value
Qualitative amount of foot observed
0 No foot formation
1 Slight foot formation
2
Quite less foot that is not visible through
naked eye
3 Visible, but less foot formation
4 Fairly small foot formation
5 Small foot formation
6 Moderate foot formation
7
Fairly large foot of X and Y dimension less
than 0.2 mm
8
Large foot with X and Y dimensions more
than 0.2 and less than 0.5 mm
9
Quite large foot with X and Y dimensions
greater than 0.5 mm
Table. 2: Qualitative Assessment of Amount of Foot in 10
Point Scale
Experi
ment set
Cutting
velocity,
Vc
(m/min)
Orthogonal
rake, α0
(degree)
Qualitative assessment of amount of
foot in 10 point scale at different exit
edge bevel angles
0o
15o
20o
25o
30o
35o
1 22 +5 8 0 1 1 3 3
2 22 -3 9 0 1 1 3 5
3 15 0 8 0 1 1 3 4
4 15 0 8 0 1 1 3 4
5 10 +5 6 0 0 1 3 3
6 10 -3 7 0 3 3 5 6
Table. 3: Results Obtained In Shaping Of Aluminium Alloy
III. DISCUSSIONS ON EXPERIMENTAL RESULTS
To investigate the effect of exit edge beveling of aluminum
alloy flats on foot formation, orthogonal shaping operation
has been done as detailed in Table 1. Test pieces are
observed with respect to the extent of foot formation after
orthogonal shaping operation. Following a 10 point scale
detailed in Table 2, observed foot is classified and results
are detailed in Table 3. Repeat tests (experiment set 3 and 4)
show identical results. Large to quite large size foot more
than 0.2 mm in size is formed at experiment set 1 through 4
when no edge bevel is provided. At a lower cutting velocity
with an orthogonal rake angle of 5o
(experiment set 5),
moderate foot is seen, whereas at a -3o
orthogonal rake used
in experiment set 6, fairly large foot is found. This
observation is expected naturally. Foot formation decreases
with the decrease in edge bevel angle, θ. At an exit edge
bevel angle, θ of 35°, visible, less to moderate foot is made
at different sets of experiments. This may be due to steep
reduction in depth of cut resulting in the possibility of
negative shear plane formation.
No foot formation occurs at 15° exit edge bevel
angle for all the six experiments in the direction of width of
cut. This may be due to less need of backup support material
resulting in less chance of the formation of negative shear
plane, as a negative shear plane is responsible for foot
formation as reported by Ramaraj et al. [5]. Along a slow
gradual bevel, depth of cut reduces gradually needing
decreasing cutting forces thereby suppressing the orientation
of shear plane. At this condition, no burr formation occurs
for the same reason. With 10 m/min cutting velocity and
orthogonal rake angle of 5°, at 20° exit edge bevel angle
also, no foot formation is seen. Hence, 150
exit edge bevel
angle may be recommended.
IV. EXPERIMENTAL VALIDATION WITH ANOVA
Analysis of variance (ANOVA) is done on the experimental
results to formulate the relationship between the process
variables and depth of foot following the steps as reported
by Montgomery [22]. The result of the analysis of variance
(ANOVA) is given in Table 4. This table shows the
relationship between the dependent variable, qfit (qualitative
depth of foot found through regression equation) and
independent variables (Vc in m/min, α0 in degree, and θ in
degree). Table 4 also depicts that this relationship has high
level of confidence, as level of significance is zero.
Regression coefficients are obtained from Table 5, and with
these, the regression equation is formed as given in equation
(1).
(1)
Table 5 shows that the variable, θ has quite high confidence
level as it has 0.000 level of significance, whereas Vc and α0
have less confidence level having significance of 0.105 and
0.002. It means that exit edge bevel angle, θ has remarkable
effect on foot formation while cutting velocity, Vc and
orthogonal rake angle, α0 have relatively less effect on foot
formation, and orthogonal rake, α0 has slightly higher
influence than cutting velocity, Vc. Therefore, exit edge
bevel angle, θ is the main variable that needs be optimized
to have the least possibility of its occurrence of foot
formation within the experimental domain.
Model
Sum of
Squares
Degree
of
Freedom
(DOF)
Mean
Square
F-
value
Significa
nce
Regression 74.132 3 24.711 46.328 0.000a
Residual 13.868 26 0.533
Total 88.000 29
Table. 4: The ANOVA Table
Model
Un-standardized
Coefficients
Standardized
Coefficients
t-value Significance
Coefficient
Standard
Error
Beta
Constant -2.444 0.649 -3.768 0.001
Exit edge
bevel
angle, θ
0.210 0.019 0.867 11.136 0.000
Orthogonal
rake, α0
-0.140 0.040 -0.270 -3.462 0.002
Cutting
velocity,
Vc
-0.0455 0.027 -0.131 -1.679 0.105
Table. 5: The ANOVA Table Showing Regression
Coefficients
Figure1show the experimental observation (qa) and that
evaluated from regression equation (qfit) regarding the
qualitative depth of foot under different machining
conditions with different exit edge bevel angles. Qualitative
depth of foot obtained from the regression equation are
found to be matching fairly closely with the experimentally
obtained values, and indicates the appropriateness of the
evaluated relationship. This raises the possibility of using

3. Experimental Observation on Reduction of Foot Formation of 4600-M Aluminum Alloy in Shaping
(IJSRD/Vol. 1/Issue 9/2013/0068)
All rights reserved by www.ijsrd.com 1973
the regression equation for predicting the extent of foot
formation in shaping operation.
Fig. 1: Comparative study of qualitative amount of foot
actual (qa) and predicted (qfit) with different exit edge bevel
angles, cutting velocities and orthogonal rakes
IV. CONCLUSIONS
Based on the observation of shaping foot formation at the
exit edge of 4600-M aluminium alloy test pieces under dry
condition, the following conclusions may be drawn:
1) Exit edge beveling of the specimen has substantial
effect on reduction of foot formation.
2) Large foot formation is seen at the exit edge bevel angle
of 35°. This may be due to quite sharp reduction in
depth of cut, causing the formation of a negative shear
plane.
3) At 15° exit edge bevel, no foot formation is noticed
under all machining conditions undertaken. It may be
due to less requirement of backup support material at
the appropriate beveled exit edge of the test piece with
slow gradual reduction in depth of cut needing
gradually reducing cutting force. Formation of no
negative shear plane may also have resulted in
suppression of foot formation.
4) Analysis of variance (ANOVA) is carried out on the
experimental data. It is observed that exit edge bevel
angle has the maximum influence on foot formation
compared to cutting velocity and orthogonal rake angle
whereas orthogonal rake angle shows slightly higher
influence than the cutting velocity on foot formation at
the exit edge. The regression equation developed by
ANOVA has good significance, and may well be used
to estimate the extent of foot formation.
5) Finally, it can be stated that an exit edge bevel angle of
15° is recommended to control foot and burr formation
in orthogonal shaping of 4600-M aluminium alloy.
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(IJSRD/Vol. 1/Issue 9/2013/0068)
All rights reserved by www.ijsrd.com 1974
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