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Chapter-4-Chips Formation

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33 views24 pages

Chapter-4-Chips Formation

Uploaded by

chapiab02
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Chapter Four

Chip Formation

By Tantigegn K.

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Mechanics of chip formation
 Cutting action involves shear deformation of work material to form
a chip, and as chip is removed, new surface is exposed:
 Basic cutting geometry:

 Orthogonal cutting: the cutting edge of the tool is straight and


perpendicular to the direction of motion. This is a two dimensional
cutting process.
 4/24/2024
Oblique cutting: the tool edge is set at angle. 2
Mechanics of chip formation
Basic cutting geometry:
 The tool in orthogonal cutting has only two elements of geometry.
 Rake angle: determines the direction that the chip flows as it is
formed from the work part.
 Clearance angle: provides a small clearance between the tool flank
and the newly generated work surface.

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Mechanics of chip formation
 As the chip is formed along the shear plane, its thickness increases to tc
from t0 (thickness of the chip prior to chip formation). From this chip
thickness or chip thickness ratio (r) is defined.

 The chip ratio is always less than 1 as the chip thickness after
cutting is always greater than the corresponding thickness before
cutting.
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Mechanics of chip formation
 The width of the work surface, W, doesn’t contribute to the analysis
in orthogonal cutting.

 The geometry of the orthogonal cutting model allows us to establish


relationship between chip ratio, rake angle and shear plane angle.

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Mechanics of chip formation
Thus, the chip ratio, r will be:

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Mechanics of chip formation

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Mechanics of chip formation

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Mechanics of chip formation

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Chip formation

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Chip formation
Actual chip formation:

 In the actual chip formation,

 The shear deformation process doesn’t occur along a plane, but


within a zone, thin shear zone which is only a few thousands on an
inch. This shear is called primary shear.

 Another shear action that occurs in the chip after it has been
formed. This additional shear is called a secondary shear.

 The formation of the chip depends on the type of material being


machined and cutting conditions of the operation.

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Chip formation

More realistic view of chip formation


 The secondary shear results from friction between the chip and the
tool as the chip slides along the rake face of the tool.
 Its effect increases with increased friction between the tool and the
chip.
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Chip formation

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Types of chip
1. Continuous chips:
 Continuous “ribbon” of metal that flows up the
chip/tool zone.
 Usually considered the ideal conditions for efficient
cutting action.
 Usually formed during cutting of ductile materials.
Example: Al ,Mg, Cu etc.
 Formed at high rake angle.
 Good surface finish are generally produced

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Types of chip
 Continuous chips are not always desirable , particularly in
automated machines.
 They get tangled around a tool and the operations has to be
stopped to clear away.
 Remedy- use of chip breaker.

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Types of chip
Conditions which favor continuous types of chips:
 Ductile work
 Fine feeds
 Sharp cutting tools
 Larger rake angle
 High cutting speed
 Proper coolant

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Types of chip
2. Continuous with built up edge:
 BUE formed when there is a chemical affinity between the work
piece and tool.
 This type of chip is common in softer non-ferrous metals and low
carbon steels.
 Favorable growth conditions such as:
 High strain hardening
 Low speed
 Large depth of cut
 Low rake angle
 High temperature

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Types of chip
Continuous with built up edge…
 BUE consists of layer of materials from work piece that are
gradually deposited on the tool.
 BUE becomes unstable and eventually breaks up, but forms grains.
 It is carried away on the tool side of the chip, the rest is deposited
on the work piece .This results poor surface finish
 BUE, periodically will be break off and removes the cutting tool.
 Tool life will be reduced.

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Types of chip
 BUE can be reduced by:-

 Increasing cutting speed;

 Decreasing the feed rate;

 Increasing the rake angle;

 Reducing friction by applying cutting fluids.

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Types of chip
3. Discontinuous chips:
 Discontinuous chips consists of segments that may be firmly
or loosely attached to each other.
 The chips occur when machining hard brittle materials such
as cast iron.
 Low rake angle and large depth of cut are major causes.
 Brittle failure takes place before any tangible plastic
deformation.
 The discontinuous nature of the chips forces vary continually
leading to vibration and chattering.
 Chattering further results in poor surface finish and loose of
tolerance.
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Types of chip

Remedy for discontinuous chips:


 Increase the rake angle,
 decrease the depth of cut,
 use medium cutting speed,
 use of cutting fluids to reduce friction.
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Types of chip

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The effect of speed in chip formation:

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Thank you!

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