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    Chip Formation: Four Basic Type of Chips in Machining Are

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    jssrikantamurthy
    There are four basic types of chips that can form during machining: discontinuous chips, continuous chips, continuous chips with built-up edge (BUE), and serrated chips. Discontinuous chips form when brittle materials like cast iron are cut. Continuous chips form when machining ductile materials like steel at high speeds. Continuous chips with BUE form when friction is high during machining ductile materials, causing chip particles to adhere to the tool rake face near the tip. BUE can have detrimental effects on surface finish, forces, power consumption, and tool life.

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    Chip Formation: Four Basic Type of Chips in Machining Are

    Uploaded by

    jssrikantamurthy
    165 views14 pages
    There are four basic types of chips that can form during machining: discontinuous chips, continuous chips, continuous chips with built-up edge (BUE), and serrated chips. Discontinuous chips form when brittle materials like cast iron are cut. Continuous chips form when machining ductile materials like steel at high speeds. Continuous chips with BUE form when friction is high during machining ductile materials, causing chip particles to adhere to the tool rake face near the tip. BUE can have detrimental effects on surface finish, forces, power consumption, and tool life.

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    tool life

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    There are four basic types of chips that can form during machining: discontinuous chips, continuous chips, continuous chips with built-up edge (BUE), and serrated chips. Discontinuous chips form when brittle materials like cast iron are cut. Continuous chips form when machining ductile materials like steel at high speeds. Continuous chips with BUE form when friction is high during machining ductile materials, causing chip particles to adhere to the tool rake face near the tip. BUE can have detrimental effects on surface finish, forces, power consumption, and tool life.

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    © All Rights Reserved
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    Download as pptx, pdf, or txt
    165 views14 pages

    Chip Formation: Four Basic Type of Chips in Machining Are

    Uploaded by

    jssrikantamurthy
    There are four basic types of chips that can form during machining: discontinuous chips, continuous chips, continuous chips with built-up edge (BUE), and serrated chips. Discontinuous chips form when brittle materials like cast iron are cut. Continuous chips form when machining ductile materials like steel at high speeds. Continuous chips with BUE form when friction is high during machining ductile materials, causing chip particles to adhere to the tool rake face near the tip. BUE can have detrimental effects on surface finish, forces, power consumption, and tool life.

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    Chip Formation

    Four Basic Type of Chips in Machining are:

    • Discontinuous chip
    • Continuous chip
    • Continuous chip with Built-up Edge (BUE)
    • Serrated chip
    Chip Formation
    Discontinuous chip
    When brittle materials like cast iron are cut, the deformed material gets
    fractured very easily and thus the Chip produced is in the form of
    discontinuous segments.
    Reasons
    • Brittle work materials
    • Low cutting speeds
    • Large feed and depth of cut
    • High tool-chip friction
    Chip Formation
    Continuous chip
    Continuous chips are normally produced when machining steel or ductile
    materials at high cutting speeds. The continuous chip which is like a
    ribbon flows along the rake face.
    Reasons
    • Ductile work materials
    • High cutting speeds
    • Small feeds and depths
    • Sharp cutting edge
    • Low tool-chip friction
    Chip Formation
    Continuous chip with Built-up Edge (BUE)
    When the friction between tool and chip is high while machining ductile
    materials, some particles of chip adhere to the tool rake face near the tool
    tip is termed as built up edge (BUE). By virtue of work hardening, BUE is
    harder than the parent work material.
    Reasons
    • Ductile materials
    • Low-to-medium cutting speeds
    • Tool-chip friction causes portions of
    Chip to adhere to rake face
    • BUE forms, then breaks off, cyclically
    Characteristics of BUE
    Built-up-edges are characterized by its shape, size and bond
    strength, which depend upon:
    • work tool materials
    • stress and temperature, i.e., cutting velocity and feed
    • cutting fluid application governing cooling and lubrication.
    BUE may develop basically in three different shapes as
    schematically shown.
    Effects of BUE Formation

    Formation of BUE causes several harmful effects, such as:

    • It unfavorably changes the rake angle at the tool tip causing


    increase in cutting forces and power consumption.

    • Repeated formation of the BUE causes fluctuation in cutting


    forces and thus induces vibration which is harmful for the tool, job
    and the machine tool.

    • Surface finish gets deteriorated.

    • May reduce tool life by accelerating tool-wear at its rake surface.


    Cutting Speed v/s Surface Roughness
    Orthogonal cutting & Oblique cutting
    Heat generation in metal cutting

    1.Primary shear zone - Where the major part of the energy is converted into
    heat.
    2. Secondary deformation zone - At the chip – tool interface where further
    heat is generated due to rubbing and / or shear.
    3.Teritiary deformation zone- At the worn out flanks due to rubbing between
    the tool and the finished surfaces.
    Merchant model for Orthogonal cutting

    Forces acting on chip during metal cutting


    Merchant model for Orthogonal cutting

    Merchant circle diagram


    Merchant model for Orthogonal cutting

    Merchant circle diagram showing various angles


    Merchant model for Orthogonal cutting

    Merchant circle diagram showing various angles


    Shear angle relationship in terms of chip thickness ratio
    & rake angle

    Chip formation process

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