Chip Formation: Introduction
Because of the importance of machining for any industrial economy, Machining Theory
has been extensively studied.
The chip formation process is the same for most machining processes, and it has been
researched in order to determine closed-form solutions for speeds, feeds, and other
parameters which have in the past been determined by the "feel" of the machinist.
With CNC machine tools producing parts at ever-faster rates, it has become important to
provide automatic algorithms for determining speeds and feeds. The information
presented in this section are some of the more important aspects of chip formation.
Reasons for machining being difficult to analyze and characterize can be summarized as
follows:
The strain rate is extremely high compared to that of other fabrication processes.
The process varies considerably depending on the part material, temperature,
cutting fluids, etc.
The process varies considerably depending on the tool material, temperature,
chatter and vibration, etc.
The process is only constrained by the tool cutter. Unlike other processes such
as molding and cold forming which are contained, a lot of variation can occur
even with the same configuration.
For all types of machining, including grinding, honing, lapping, planing, turning, or
milling, the phenomenon of chip formation is similar at the point where the tool meets the
work.
Below are illustrated categories of chip types.
MECHANISM OF CHIP FORMATION, TYPES OF CHIP, CHIP BREAKER
Mechanism of Chip formation:-
· The tool is considered stationary, and the workpiece moves to
the right. The metal is severely compressed in the area in front of the cutting too
l
· This causes high temperature shear and plastic flow if the metal is ductile.
· When the stress in the workpiece just ahead of the cutting tool reaches a value
exceeding the ultimate strength of the metal, particles will shear to form a chip
element which moves up along the face of work.
· The outward or shearing movement of each successive element is arrested by w
ork hardening and the movement transferred to the next element.
· The process is repetitive and a continuous chip is formed having a highly comp
ressed
and burnished underside, a minutely serrated top side caused by the shearing act
ion.
· The place along which the element shears is called the shear plane.
· Thus the chip is formed by plastic deformation of the grain structure of the
metal along the shear
Types of chip
· The form and dimension of a chip in metal machining indicates the nature and
quality of a particular machining process, but the type of chip formed is greatly
influenced by the properties of material cut and various cutting conditions.
· In engineering manufacture particularly in metal machining processes hard britt
le metals have a very limited use, and ductile metals are mostly used.
· Chips of ductile
metals are removed by varying proportions of tear, shear and flow. This results i
n three general types of shapes.
Ø The discontinuous ( segmental form)
Ø The continuous or ribbon type.
Ø The continuous with built - up edge.
· Discontinuous or segmental chips consist of elements fractured into fairly
small pieces ahead of the cutting tool.
· This type of chip is obtained in machining most brittle material, such as cast iro
n and bronze. These materials rupture during plastic deformation, and form
chips as separate small pieces.
· As these chips are produced, the cutting edge smoothes over the irregularities a
nd
fairly good surface finish is obtained. Tool life is also reasonably good and pow
er consumption is low.
· Discontinuous chips can also be formed on some ductile metals only under cert
ain conditions particularly at very low speeds and if the coefficient of friction is
low.
With ductile metals, however the surface finish is bad and the tool life is short.
· Conditions tending to promote its formation include: brittle metal, greater dept
h of cut, low cutting speed and small rake angle.
· Continuous chips consist of element bonded firmly together without being
fractured.
· Underside of continuous chip has small notches while the lower side, which sli
des over the tool face, is smooth and shiny.
· The continuous form is considered most desirable for low friction at the tool
chip interface, lower power consumption, long tool life and good surface finish.
· Factor favorable to its formation are: ductile metal, such as mild steel, copper,
etc.,
fine feed, high cutting speed, large rake angle, keen cutting edge, smooth tool fa
ce and an efficient lubrication system.
· The term built up edge implies the building up of a ridge of metal on the top su
rface of the tool and above the cutting edge.
· It appears that, when the cut is started in ductile metals, a pile of compressed an
d highly stressed metal forms at the extreme edge of the tool.
· Owing to the high heat and pressure generated there, this piled up metal is weld
ed to the cutting tip and forms a ‘false’ cutting edge to the tool.
This is usually referred to as the ‘built up edge’.
· Conditions tending to promote the formation of built up edges include: low cutt
ing speed, low rake angle, high feed, lack of cutting fluid and large depth of cut.
Chip Breaker
· A continuous type chip form a long cut is usually quite troublesome.
· Such chips foul the tools; clutter up the machine and workplace, besides being
extremely difficult to remove from the swarf tray.
· They should be broken into comparatively small pieces for ease of handling an
d to
prevent it from becoming a work hazard, hence the chip breakers are used to red
uce the swarf into small pieces as they are formed.
· The fact that the metal is already work hardened helps the chip breaker to perfo
rm effectively.
· Various types of chip breakers are made, but all of them consist mainly of a ste
p or groove ground into the leading edge of the tool or a piece of cutting tool
material clamped on top of the cutting tool.
· In normal shop practice common methods of breaking the chips are summarize
d as follows:
Ø By clamping a piece of sheet metal in the path of the coil.
Ø By a stepped type breaker in which a step is ground on the face of the tool along
the cutting edge.
Ø By a groove type breaker in which a small groove is ground behind the cutting
edge.
Ø By a clamp type breaker in which a thin carbide plate or clamp is brazed or
screwed on the face of the tool.
