MEMEE44: CNC Technology

and Programming
Dr. Andriya Narasimhulu
Assistant Professor
Department of Mechanical Engineering
Netaji Subhas University of Technology
Google Class Code:
 What is CNC Machining?
● CNC stands for Computer Numerical Control.

● The CNC machining process is a manufacturing process that

creates the final part by removing material using a cutting tool.

● There are many different types of CNC machines with numerous

cutting tool options for a range of jobs and applications.
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What are the different industries that use

CNC machining processes?

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Aerospace Industry
● Airfoils
● Antennae
● Landing gear
● Manifolds
● Bushings
● Radiofrequency Suppression Materials
● Electrical Connectors
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Automotive Industry
● Gearboxes
● Axles
● Engine parts
● Valves
● Cylinder Blocks
● Dashboard panels
● Gas gauges
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Marine Industry
● Deck structures
● Hull structures
● Trimmings and Joints
● Ribs
● Stringers
● Interior furnishings like:
● Kitchen Countertops
● Storage Cabinets
● Wraparound seating 9
Electronics Industry
● Electronic components
● PCBs
● Housings
● Jigs
● Semiconductor manufacturing process
● Wafer plates
● Gas distribution channels
● Solder flex stencils
● Wafer carriers
● Heat sinks 10
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Smartphones
● Smartphone bodies (both metal and plastic)
● Smartphone cases
● Touch-sensitive screens
● Rear glass panels
● Aesthetic etching
● Supported accessories
● Internal housing and fixtures
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Military and Defense Industry
● Main rotor hubs
● Couplers
● Seat frames for land and air transportation
● Clamshells
● Flanges
● Transmission parts
● Missile components
● Helicopter components
● Retainer rings
● Ammunition hoisting components 13
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Healthcare Industry
● Bone screws
● Bone plate
● Surgical instruments
● Cutters
● Holders
● Forceps
● Clamps
● Blades
● Pacemakers
● Prosthetics 15
Energy Industry
● Valves ● Bearings
● Pistons ● Hydro generators
● Cylinders ● Generator housings
● Rods ● Bushings
● Pins ● Solar panel frames
● Turbine blades

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Dental Equipment
● Dental prostheses
● Implant abutment
● Dental cap
● Framework
● Bridgework
● Implants guide
● Orthodontic trays
● Screwed-in bar
● Crown
● Dentures
● Telescope crown
● Inlay core
● Implants

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Jewelry
● Rings
● Molds
● Casting models
● Engravings
● Marble faceting
● Jewelry polishing

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Other Industries
Furniture
Robotics and Automation
Footwear
Research and Development
Musical Instruments
Agriculture
Semiconductors
Food and Beverage
Tooling
Metal Fabrication
Hybrid Manufacturing
Construction And Architecture

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 Unit-I

Introduction: NC and CNC, Industrial applications of CNC, Economic

benefits of CNC, CNC as a management control. Design difference
between conventional and CNC machine tools, Classification of CNC
machine tools, Swarf control.

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 Unit-II

Control considerations: Open and closed loop control, fundamental

problems of control, types of positional control, machine tool control,
computer considerations, binary system, CNC code system, data input.

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 Unit-III

Drawing considerations: Drawing implications for CNC, datums and

coordinate systems, documentation for CNC machining, geometrical
tolerances.

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 Unit-IV

Machining considerations: Tooling for CNC, cutting tool material, hard

metal insert tooling, chip breakers, non-insert tooling, tooling systems,
speeds and feeds, cutting speed and spindle speed calculations, feed rate
calculations, tool life calculations, work holding and setting, principles of
location, principles of clamping, work holding devices.

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 Unit-V

Programming considerations: Part programming language, concept of a

stored program, preliminaries to part programming, CNC control systems,
part programming terminology, part program codes and formats, part
programming procedure, control system assumption, programming
positional moves, linear and circular interpolation, canned cycles,
repetitive programming, loops, subroutines, macros, tooling offsets,
compensations, part program verification, manual and computer aided
part programming system.

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Recommended Books

1. Introduction To Computer Numerical Control - Leatham-Jones, Wiley & Sons.

2. Computer Numerical Control; Concepts and Programming – Seames, Thomson

Delmar.

3. CNC Machining Technology - Smith, Springer London.

4. Machining and CNC Technology - Fitzpatrick, McGraw-Hill Higher Education

5. CNC Machining; Building, Programming, and Implementation - Overby,

McGraw-Hill.

6. Programming of CNC Machines - Evans, Industrial Press, Inc

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UNIT-I

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 Introduction
Material cutting techniques

Figure 1.1(a) Dividing cutting action;

b) shaving cutting action

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 Material removal techniques on machine tools
(a) Cutting with a single-point metal tool
(b) Cutting with multipoint metal tools
(c) Cutting with abrasives
(d) Electrochemical machining
(e) Electric-discharge machining
(f) Ultrasonic impact machining
(g) Laser, plasma and electron beam machining.

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 Application of Numerical Control

(a) Press tool work on turret presses

(b) Flame cutting on oxyacetylene machines
(c) Control of plotters
(d) Measurement and inspection equipment
(e) Control of robots.

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 Kinematic principles of operation of machine tools

Generation

Generation of cylinder

Methods of generating cylinders

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 Kinematic principles of operation of machine tools

Generation of forms requiring

synchronized movements

Copying

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 Kinematic principles of operation of machine tools

Forming

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Surface texture

Surface texture produced with

single point tools

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 Economic benefits of CNC,

1. CNC Machining Generates Minimal to No Waste

2. CNC Machining Is More Accurate and Has No Defects
3. CNC Machining Offers More Rapid and Effective Production
4. CNC Machining Makes Assembly Faster
5. CNC Machining Separates Machines From People And Reduces
the Risk That Would Otherwise Arise
6. CNC Machining Uses Little Energy
7. CNC Machining Reduces Production Costs

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CNC as a management control

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 Levels of control
Control of machine tools involves:
(a) The applying of power
(b) The guiding or limiting of the movement of the tool or work
(c) The selection of the rate of movement of the tool and/or work
(d) The selection of manufacturing facilities, the clamping of work or tool,
and so on.

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 Different Controls managed in CNC

Zero level of control

First level of control
Second level of control
Third level of control
Fourth level of control
Fifth level of control: numerical control

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 Progression in CNC Development
First-generation numerical control
Second-generation numerical control: NC machine tools

Third-generation numerical control: CNC and DNC machine tools

Machining centres
Turning centres

Mill-turning centres

Sheet metal working

CNC grinding

CNC spark erosion

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What’s CNC Machining?

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 Computer Numerical Control (CNC)

● CNC (computer numerical control) machining is a

subtractive manufacturing process.
● It employs computerized controls and machine tools to
remove material layers from a stock piece to produce
custom-designed parts.
● The CNC machining technology integrates traditional
machining with CNC technology, computer-aided design,
and auxiliary manufacturing processes.

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 Computer Numerical Control (CNC)

● First, designers use Computer-Aided Design (CAD) software to create

a digital 3D model of the desired part. Next, a skilled programmer
translates the CAD model into a series of instructions (called G-code)
that the CNC machine can understand. With the program loaded, the
CNC machine securely clamps a block of raw material (workpiece)
and uses computer-controlled motors to move the cutting tools along
precise paths.
● The cutting tools progressively remove material from the workpiece,
transforming it into the final shape dictated by the CNC machining
program. This translates to high-quality CNC machined parts with
precise dimensions and intricate details. 41
 Advantages of CNC Machining
Precision and Repeatability

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 Advantages of CNC Machining
● Precision and Repeatability
● Ability to Produce Complex Shapes and High-Complexity Parts
● Reduced Human Error and Enhanced Safety
● Efficient for High-volume Production

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Disadvantages of CNC Machining
● Higher Initial Investment and Maintenance Cost
● Requirement for Skilled Operators and Programmers

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Disadvantages of CNC Machining

● Higher Initial Investment and Maintenance Cost

● Requirement for Skilled Operators and Programmers
● Less Cost-effective for Very Small Batches

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What’s Conventional Machining?

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 Advantages of Conventional Machining
● Lower Initial Investment
● Flexibility for Small Batch Production and Prototypes
● Easier to Change or Adjust in Mid-process
● Suitable for Simple Parts and Operations

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Disadvantages of Conventional Machining
● Lower Precision and Repeatability Compared to CNC
● Higher Potential for Human Error
● Slower Production Rate and Efficiency
● Requires Highly Skilled Operators

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Design difference between conventional and
CNC machine tools

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 Design difference between conventional and
CNC machine tools
● Precision and Complexity of Parts
● Material Type
● Production Volume and Efficiency

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Design difference between conventional and
CNC machine tools
● Precision and Complexity of Parts
● Material Type
● Production Volume and Efficiency
● Cost-Effectiveness
● Skill Requirements for Operation

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Is CNC Machining Better than Conventional
Machining?

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 CNC Supports Management
It is also possible with CNC systems to obtain information that is useful for
management purposes such as:

(a) Number of components completed (f) Time that a particular tool has been in use

(b) Number of different set-ups (g) Time that the spindle has been running

(c) Time for setting up a particular job (h) Time that a machine has not been
working, and reasons
(d) Time per component
(i) Fault diagnosis for maintenance purposes
(e) Time that material is actually being
removed (j) Maximum load during machining.

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 Direct numerical control (DNC)
● DNC is a system containing a number of numerically controlled
machines rather than a single machine. All the machines are linked to
a mainframe computer which sends the information to the individual
machines as required.
● There can be a number of different types of machine linked to the one
mainframe computer.
● The computer is programmed to be able to select the order of
manufacture of the components.
● DNC is capable of being integrated into the running of a complete
factory, provided that the orders for equipment or parts are entered
into the computer's memory, and that all the part programs have been
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written.
 Types of DNC
● Minimum cost: only one point of control
● Maximum flexibility : each machine has its own dedicated computer,
and the main computer provides the complete program for the
component.

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 Flexible manufacturing cells

● A complete factory-wide flexible manufacturing system is extremely

expensive. A more economic application is a flexible manufacturing
cell.
● The term flexible refers to the adaptability provided by the computer of
economically machining a variety of single components or small
batches of components to fulfil the production requirements of the
firm.

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 Flexible manufacturing cells
(a) A computer with software for controlling the cell
(b) A CNC machining centre and a CNC turning centre (mill-turning
centre) if required for the type of work being produced. These machines
must be equipped with tool magazines, automatic tool changers (ATC)
and preferably automatic tool setting facilities

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 Flexible manufacturing cells
(c) Automatic work loading and unloading facilities for machining centres such as
an automatic pallet changer (APC) or automatic work carrying (AWC) vehicle;
work changing facilities for turning centres such as automatic bar changing,
robotic arm or gantry loaders. Preferably all the machines should have automatic
work location setting and checking facilities

(d) A station for the removal of completed work and renewal of fresh work

(e) Automatic swarf removal.

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 Cost of manufacture
● Variable costs : These may also be referred to as production costs or
running costs. They are dependent on the number of components to
be produced: the more components produced, the more the variable
costs.
● Fixed costs.: These are the costs that have to be paid regardless of
the number of components to be produced. They may be referred to
as preproduction costs, lead time costs or capital costs.
● Lead time is the term used to describe the time leading up to actual
manufacture. It is the time required to prepare tools and part
programs; in some firms, set-up time may be included in lead time.
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 Cost of manufacture : Variable Costs
(a) Material
(b) Plant or machine
(c) Labour
(d) Services or overheads.

cost per component

= material cost + machine cost + labour cost + overheads cost

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 Cost of manufacture : Variable Costs
(a) Material Cost
The material cost of a particular component is the same regardless of the
machining process, and can be regarded as a constant for the
component.

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Cost of manufacture : Variable Costs
(b) Machine and plant cost
The material cost of a particular component is the same regardless of the
machining process, and can be regarded as a constant for the
component.

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 Cost of manufacture : Variable Costs

(b) Machine and plant cost

Machine Rule

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Cost of manufacture : Variable Costs

(c) Labour costs

Labour costs are the wages paid to the people directly involved in the
manufacture of the component. The wages of the people concerned with
the supervision or organization of the manufacture are part of the
overheads, and are often called salaries.
labour cost per component = labour rate per hour x floor-to-floor time per
component

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 Cost of manufacture : Variable Costs
(c) Overheads or services

It is difficult to calculate accurately how much of the wages of all the other various
personnel in the firm, and the cost of the facilities provided, should be allocated to a
component. In order that the costs are recovered it is standard prac tice to specify the
overheads as a percentage of the major direct factor involved in the production of a
component.

Traditionally it is the productive labour cost to which the overheads are related; this is
mainly because the labour cost is usually the largest and the most controllable cost.

Where the machine costs are the largest single item, consideration is given to relating
the overheads to the machine costs.

The percentage for overheads varies considerably with different firms and range from
200 to 800 per cent. 66
Cost of manufacture : Fixed Costs
Break-even chart for two machines

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 Break Even Point Calculation
Let the quantity and the total cost for both machines at the break-even point
be Qbe and Τ respectively.

Let the fixed costs for machine A be FA and for machine Β be FB, and

Let the cost per component on machine A be CA and on machine Β be CB

Then at the break-even point the total cost for machine A is given by:

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Break Even Point Calculation
Similarly, the total cost at break-even point for machine Β can be specified as:

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Example
It is possible to produce a component using (a) a hand-operated centre
lathe (b) a cam-operated automatic lathe (c) a CNC turning centre. Given
the following information, the range of work for which each machine is the
most economic is to be determined. Overheads are to be taken as 300
per cent on productive labour.

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Example

The set-up time for the centre lathe is the time required to determine the
readings of the index dials for the diameters required. The labour rate for
the cam auto is half the setter's rate plus half the feeder's rate. The feeder
is a semi-skilled person who is responsible for ensuring that the automatic
lathe is kept loaded (fed) with the work material. An automatic lathe setter
generally looks after a minimum of two machines.
Since it is the same component that is being produced, the material costs
will be the same for all machines. Therefore it is intended to neglect the
material costs as they will have no influence on the break-even quantity.

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Solution

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Solution

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Solution

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Solution

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These break-even quantities can be interpreted as follows:
(a) For quantities up to and including 29, the centre lathe is the most
economic.
(b) For quantities between 30 and 628 inclusive, the CNC turning centre is
the most economic.
(c) For quantities of 629 and more the cam automatic is the most
economic.

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Classification of CNC machine tools

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 Classification of CNC machine tools
According to the point of movement of the CNC machining
machine tool:
(1) Position control system Point control
(2) Linear control system
(3) Profile control system / Contour control

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 Position control system
● Only the position of the control tool can be moved from one point to another, and
in the process of not moving.
● CNC machining such as jig boring machine, drilling machine, punching machine,
etc. Coordinates have high positioning accuracy.
● In order to improve the efficiency of CNC machining, the CNC machining machine
tool group with the highest feed speed is used to move, graded or continuously
decelerated before closing the anchor point, so that the low speed reaches the
finish line, thereby reducing the movement of CNC machining
● The inertia of the parts is over-adjusted, causing positioning errors. Movement in
the positioning process does not require CNC machining, so there is no
requirement for the trajectory.

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 Linear control system
The linear control system refers to the precise movement that is controlled
from one position to another at a certain speed along the direction parallel
to the axis. Also known as point linear motion control system.

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 Profile control system
● It is to control two or more axes at the same time (two semi-axis, two-axis,
three-axis, 4-axis, five-axis linkage). It not only controls the start and end
coordinates of the moving parts of the machine, but also controls the entire
process
● The speed, direction and displacement of each link, namely the processing of
trajectory control, formulate the required contour.
● The slope of the trajectory is any straight line, arc, spiral, etc.
● This kind of machine tool numerical control device has the most complete
functions. It can control more than two coordinates and coordinate linkage,
and can control points and lines.

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 Classification of CNC machine tools
According to the number of axes, CNC machine tools can generally
be divided into five categories:
● 2-axis CNC machine tools,
● 2.5-axis CNC machine tools,
● 3-axis CNC machine tools,
● 4-axis CNC machine tools and
● 5-axis CNC machine tools.

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 2 Axis CNC Machining Machine
A machine is only allowed to enter two axes, such as a lathe,
and the tool moves in two directions, such as X and Z.

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 2.5-Axis CNC Machining Machine
● It is also a three-axis system, but the movement is not
three-dimensional.
● The X-axis and Y-axis first move to the position, and then
the third axis starts to work, such as drilling machines and
tapping machines.

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 3-Axis CNC Machining Machine
● Three-axis (X, Y, and Z) move simultaneously in three
dimensions.
● It is the most widely used and most versatile machine tool.
It can achieve high precision and high precision, and can
be used for automatic/interactive operations and milling
grooves. Drilling and cutting sharp edges.

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 4-Axis CNC Machining Machine
● A three-axis machine tool that rotates again on the A-axis
or B-axis. Common examples are vertical or horizontal
machine tools.
● In the case of 4-axis CNC machining, milling is performed
on the additional axis, and the operations on X, Y, and Z
are the same as the three-axis system, and the rotation on
the A or B axis is performed around the X axis.

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 5-Axis CNC Machining Machine
● A three-axis CNC machining machine tool that additionally rotates in
two directions (Y and Z) on the A-axis and B-axis, respectively, is
rotated by the bed and the spindle movement (pivot point).
● The 5-axis machine tool is an advanced CNC machining machine.
● Its multi-dimensional rotation and tool movement allow the creation of
precise and complex CNC machining parts.
● This is due to improved access to the bottom and deep pockets,
unparalleled finish and speed, usually used in aviation Advanced
applications such as aerospace components, artificial bones, titanium
parts, oil and gas machinery parts, and military products.
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 Multi-Axis CNC Machines
● These machines go beyond five axes and can have up to
9 or more axes.
● Multi-axis CNC machines are used in advanced
aerospace, medical, and automotive applications.

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 Classification of CNC machine tools
Divided by servo system control mode
1. Open loop control CNC machine tool
Low price, poor accuracy and stability.

2. Semi closed loop control CNC machine tool

High precision and stability, moderate price and most common
application.

3. Closed loop control CNC machine tool

High precision, difficult to control stability and high price. 92
 Classification of CNC machine tools
Classification by processing method

● According to different cutting methods, CNC machine tools can be divided

into CNC lathe, CNC milling machine, CNC drilling machine, CNC boring
machine, CNC grinding machine, etc.
● Some CNC machine tools contain more than two cutting functions, such
as turning center focusing on turning and taking into account milling and
drilling; Boring and milling machining center with milling, boring and
drilling functions and with tool magazine and automatic tool change
device (hereinafter referred to as machining center).
● In addition, there are various functions and different types of NC
machining machines, such as NC WEDM, NC EDM forming, NC laser
machining, plasma arc cutting, flame cutting, NC plate forming, NC press,
NC plate shearing machine, NC hydraulic machine and so on. 93
 Classification of CNC machine tools
Classified according to the functional level of CNC system

CNC system is generally divided into three grades: advanced type, universal type
and economic type. In fact, there is no exact grade limit. Reference evaluation
indexes include CPU performance, resolution, feed speed, number of linkage
axes, servo level, communication function and man-machine dialogue interface.

1. Advanced CNC system

The advanced CNC system in the classification of CNC machine tools adopts 32-
bit or higher performance CPU, the number of linkage axes above five axes, and
the resolution ≤ 0.1 μ m. Feed speed ≥ 24m / min (resolution 1) μ M) or ≥ 10m /
min (resolution 0.1 μ M), digital AC servo drive, map high-performance
communication interface, networking function and three digit dynamic graphic
display function. 94
 Classification of CNC machine tools
Classified according to the functional level of CNC system

2. Universal CNC system

In the classification of CNC machine tools, the popular CNC system adopts 16
bit or higher performance CPU, the number of linkage axes below five axes,
and the resolution is 1 μ M, feed speed ≤ 24m / min, AC and DC servo drive,
RS232 or DNC (distributed numerical control) communication interface, CRT
character display and plane linear graphic display.

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 Classification of CNC machine tools
Classified according to the functional level of CNC system

3. Economical CNC system

In the classification of CNC machine tools, the economical CNC system is
controlled by 8-bit CPU or single chip microcomputer. The number of linkage
axes below 3 axes is 0.01mm, the feed speed is 6-8min, driven by stepping
motor, with simple RS232 communication interface and displayed by nixie
tube or simple CRT characters.

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Swarf Control

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 Swarf Control
● When continuous strip swarfs are produced in processing,
it is not only easy to scratch the surface of the workpiece
and damage the blade, but also threaten the safety of the
operator.
● Therefore, it is very important to take necessary
technological measures to control the swarf type and
swarf breakage in the mechanical processing industry.

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 Swarf Control

● Because swarfs are the product of swarf layer

deformation, changing cutting conditions is an effective
way to change the types of swarfs and achieve swarf
breaking.
● The factors affecting swarf processing conditions mainly
include workpiece materials, tool geometry angle and
swarf consumption.

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 Swarf Control
General swarfs need to satisfy the following basic conditions:

1. swarfs shall not be entangled on cutting tools, workpieces and their

adjacent tools and equipment.

2. swarfs should not splash to ensure the safety of operators and observers.

3. When finishing, swarfs can not scratch the machined surface of the
workpiece, which affects the quality of the machined surface.

4. Guarantee the preset durability of the cutter, and do not wear out
prematurely and try to prevent its damage.

5. When the swarf flows out, it does not interfere with the injection of cutting
fluid; the swarf will not scratch the machine guide or other parts.
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 Swarf Control

Classification of swarf shapes

Due to the different degree of plastic deformation, different

kinds of swarfs may be produced, as shown in Figure 1.
When processing plastic materials, band swarfs, nodal swarfs
or granular swarfs are mainly formed. When processing brittle
materials, fragmentary swarfs are generally formed.
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 Swarf Control

Classification of swarf shapes

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 Swarf Control

1. Band swarfs: Band swarfs are continuous, smooth bottom and fluffy back, as
shown in Fig. 1-1a.

● Such swarfs are easily produced when plastic metal materials are machined
with larger rake angle cutters at higher cutting speed.
● It is the product of insufficient deformation of cutting layer.
● When strip swarfs are produced, the cutting process is smooth and the
surface roughness of the workpiece is small, but the swarfs are not easy to
break, which often causes winding, roughening of the workpiece and even
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affects the operation, so the swarf breaking problem can not be ignored.
 Swarf Control
2.Nodular swarf: Nodular swarf is a kind of swarf with smooth
bottom, obvious cracks on the back and deep cracks, as shown in
Fig. 1-1b.

● Such swarfs are easily produced when plastic materials are

machined at a lower cutting speed with a tool with reduced rake
angle.
● It is the product of sufficient deformation of the swarf layer and
has reached the degree of shear.
● When nodular swarfs are produced, the swarfs work unsteadily
and the surface roughness of the workpiece is relatively large. 105
 Swarf Control
3. Granular swarfs: Granular swarfs are uniform granular swarfs, as
shown in Fig. 1-1c.

● When using small rake angle tool to process plastic metal

materials at very low cutting speed, it is easy to produce such
swarfs.
● It is the product of fully deformed cutting layer, which achieves the
shear failure of material and makes swarfs break along the
thickness.
● When granular swarfs are produced, the cutting work is not stable
and the surface roughness of the workpiece is relatively large. 106
 Swarf Control
4.fragment swarfs: fragment swarfs are irregular fine-
grained swarfs, as shown in Fig. 1-1d.

● When cutting brittle materials, the swarf formed by the

sudden cracking of the cutting layer after elastic
deformation hardly passes through the plastic deformation
stage.
● When crushing swarfs are formed, the cutting work is
unstable, the blade is subjected to greater impact force,
and the machined surface is rough and uneven. 107
 Swarf Control
● It can be seen from the above that the types of swarfs
vary with the workpiece materials and cutting conditions.
● Therefore, in the process of processing, we can judge
whether the swarf condition is suitable or not by observing
the swarf shape.
● We can also change the swarf shape by transforming the
cutting condition, so that it can be transformed to the
direction beneficial to production.

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 Swarf Control
Principle of swarf breaking

● In metal cutting process, whether swarfs are easy to break

is directly related to the swarf deformation.
● Therefore, the study of swarf breaking principle must start
with the study of the swarf deformation law.

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 Swarf Control
Principle of swarf breaking

● Swarfs formed in the cutting process will have higher hardness and
lower plasticity and toughness due to relatively large plastic
deformation.
● This phenomenon is called cold hardening. After cold hardening,
swarfs become hard and brittle, and are easy to break when
subjected to alternating bending or impact loads.

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 Swarf Control

Principle of swarf breaking

● The larger the plastic deformation the swarf undergoes, the more obvious the
hardness and brittleness phenomena are, and the easier it is to break.
● When cutting materials with high strength, high plasticity and high toughness
which are difficult to break swarfs, we should try to increase the deformation of
swarfs in order to reduce their plasticity and toughness, so as to achieve the
purpose of swarf breaking.

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 Swarf Control
Principle of swarf breaking

swarf deformation can be divided into two parts:

● The first part is formed in the cutting process, which we call

basic deformation.
● The swarf deformation measured by free cutting with flat rake
face turning tool is close to the value of basic deformation.
● The main factors affecting the basic deformation are tool rake
angle, negative chamfering and cutting speed.
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 Swarf Control
Principle of swarf breaking

swarf deformation can be divided into two parts:

● The smaller the front angle, the wider the negative chamfer and
the lower the cutting speed, the larger the swarf deformation
and the better the swarf breaking.
● Therefore, reducing the front angle, widening the negative
chamfer and reducing the cutting speed can be used as
measures to promote swarf breaking. 113
 Swarf Control
Principle of swarf breaking

swarf deformation can be divided into two parts:

● The second part is the deformation of swarfs in the process

of flow and curling, which we call additional deformation.
● Because in most cases, only the basic deformation in the
cutting process can not make swarfs break, it is necessary to
add another additional deformation in order to achieve the
purpose of hardening and breaking.
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 Swarf Control
Principle of swarf breaking

swarf deformation can be divided into two parts:

● The simplest way to force swarfs to undergo additional

deformation is to grind (or press) a certain shape of swarf
breaking groove on the rake face to force swarfs to curl and
deform when flowing into the swarf breaking groove.
● Swarfs are further hardened and embrittled after additional re-
crimping deformation, and are easily broken when they collide
with the workpiece or the flank. 115
 Swarf Control
Swarf breaking method

● The fundamental reason for swarf breakage and

continuity lies in the deformation and stress during swarf
formation.
● When the swarf is in an unstable deformation state or the
swarf stress reaches its strength limit, the swarf will break.
● Usually, the swarf will break after curling.

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Swarf breaking method

● Reasonable selection of tool geometry angle, cutting

parameters and swarf breaking groove are commonly
used swarf breaking methods.

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Swarf breaking method

1. Reducing the rake angle and increasing the principal deviation

angle: the rake angle and the principal deviation angle are the geometric
angles of the tool which have great influence on swarf breaking.

● Reduce the front corner, increase swarf deformation, easy swarf

breaking.
● Because small rake angle grinding will increase cutting force and limit
the improvement of cutting parameters, tool will be damaged or even
“stuffy” when it is serious.
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Swarf breaking method

1. Reducing the rake angle and increasing the principal deviation angle:

● Generally, swarf breaking is not only done by reducing rake angle.

Increasing the main deviation angle can increase the cutting thickness
and easy swarf breaking.

For example, under the same conditions, 90 degree knife is easier to break
swarfs than 45 degree knife. In addition, increasing the main deflection angle
is beneficial to reduce the vibration in processing. Therefore, increasing the
main deflection angle is an effective swarf breaking method. 119
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Swarf breaking method

2.Reducing cutting speed, increasing feed and changing

cutting parameters are another measures for swarf breaking.

● Increasing the cutting speed will make the bottom metal of the
swarf soft and the swarf deformation insufficient, which is not
conducive to swarf breaking; reducing the cutting speed will
lead to swarf breaking.
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Swarf breaking method

2.Reducing cutting speed, increasing feed and changing cutting

parameters are another measures for swarf breaking.

● Therefore, in turning, swarfs can be broken by reducing the spindle

speed and cutting speed. Increasing feed can increase cutting
thickness and easy swarf breaking.
● This is a common swarf breaking method in processing, but it should
be noted that with the increase of feed, the surface roughness of the
workpiece will increase significantly.
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Swarf breaking method

3. Open swarf breaking groove: swarf breaking groove

refers to the groove made on the rake face of the tool.

The shape, width and oblique angle of swarf breaking groove

are all factors affecting swarf breaking.

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Swarf breaking method

3. Open swarf breaking groove:

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Swarf breaking method

3. Open swarf breaking groove:

The commonly used swarf breaking grooves are three grooves, i. e.
folded line, straight line and circular arc, and full circle arc, as shown in
Figure 2.

When cutting carbon steel, alloy steel and tool steel, folded line, straight
line arc and swarf breaking groove can be selected; when cutting high
plastic material workpiece, such as pure copper, stainless steel
workpiece, full circle arc swarf breaking groove can be selected. 124
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Width of swarf breaking groove
● The width of swarf breaking groove has a great influence on
swarf breaking.
● Generally speaking, the smaller the groove width is, the
smaller the curling radius of the swarf is, the greater the
bending stress on the swarf is, and the easier it is to break.
● Therefore, smaller swarf breaking groove width is beneficial
to swarf breaking.
● But the width of swarf breaking groove must be considered
in connection with the cutting depth and feed.
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Width of swarf breaking groove
● C-shaped swarfs can be formed if the width of swarf
breaking groove and feed rate are basically appropriate.
● If the swarf coiling groove is too narrow, it is easy to cause
swarf blocking, which increases the load of turning tool
and even damages the cutting edge; if the swarf coiling
groove is too wide and the cutting curling radius is too
large, the cutting deformation is not enough, and it is not
easy to break, and often does not flow through the bottom
of the groove to form continuous strip swarfs. 126
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Width of swarf breaking groove
● The width of the swarf groove should also be appropriate
to the cutting depth.
● Otherwise, when the groove is too narrow, it will appear
that the swarf width is not easy to curl in the groove, and
the swarf will not flow through the bottom of the groove to
form banded swarfs.
● When the groove is too wide, the swarf becomes narrow,
the flow is more free, the deformation is insufficient, and it
does not break.
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Width of swarf breaking groove

● In order to obtain satisfactory swarf breaking effect, the
appropriate width of swarf breaking groove should be
selected according to the specific processing conditions.
● For materials with lower hardness, slots should be
narrower, whereas slots should be wider.

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THE END

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