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Theory of Metal Cutting

The document discusses metal cutting, a process of removing unwanted material from metal blocks to achieve desired shapes, surface finishes, and tolerances. It explains chip formation, types of chips (discontinuous, continuous, and built-up edge), and the factors influencing chip characteristics. Additionally, it covers the importance of chip breakers to manage chip size and safety during machining.

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johnchanje2
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11 views10 pages

Theory of Metal Cutting

The document discusses metal cutting, a process of removing unwanted material from metal blocks to achieve desired shapes, surface finishes, and tolerances. It explains chip formation, types of chips (discontinuous, continuous, and built-up edge), and the factors influencing chip characteristics. Additionally, it covers the importance of chip breakers to manage chip size and safety during machining.

Uploaded by

johnchanje2
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 PPT, PDF, TXT or read online on Scribd
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INTRODUCTION

INTRODUCTION
Metal cutting is the process of producing work piece by removing
unwanted material from a block of metal in the form of chips. The
major drawback of the process is loss of material in the form of
chips.
The process is basically adopted because of the following reasons.
a) To get higher surface finish.
b) To achieve close tolerance.
c) To get complex geometric shapes.
d) Some times it may be economical to produce a component by
machining process.
Cutting Tool
Single point cutting tool
- Classification
 Has one cutting edge
Multipoint cutting tool
 Large number of cutting edges or points. E.g.: milling cutter,
drill, breaches
Turning tool
Rounding nose V threading
turning tool tool

Left hand Round hand

Facing tool Necking or Form tool


parting tool

© mjk
CHIP FORMATION
The metal is severely compressed in the area in front of the cutting
tool.
This causes high temperature shear and plastic flow if the metal is
ductile. When the stress in the work piece 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 the work.
The outward or shearing movement of each successive element is
arrested by work hardening and the movement transferred to the next
element. The process is repetitive and a cutting forces.
In conventional turning process the force system in the general case
of conventional turning process.
TYPES OF CHIP
TYPES OF CHIP
The form and dimension of a chip in metal machining indicate the
nature and quality of a particular machining process, but the type of
chip formed is greatly influenced by the properties of the material cut
and various cutting conditions.

This results in three general types of shapes:


1. The discontinuous or segmental form.
2. The continuous or ribbon type.
3. The continuous with built-up edge.
Discontinuous or segmental chips
This type of chip is obtained in machining most brittle materials,
such as cast iron 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 and a fairly good finish is obtained.
Tool life is also reasonably good, and the power consumptions low.
Discontinuous chips can also be formed on some ductile metals only
under certain conditions particularly at very low speeds and if the
coefficient of friction is low.
Continuous chips
Under the best conditions the metal ‘ flows by means of plastic
deformation, and gives a continuous ribbon of metal which, under
the microscope, shows no signs of tears or discontinuities.
The upper side of a continuous chip has small notches while the
lower side, which slides 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.
The term built-up
It appears that, when the cut is started in ductile metals, a pile of
compressed and 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 welded to the cutting tip and forms a “false” cutting edge to
the tool.
This is usually referred to as the “built up edge”.
At very high speeds, usually associated with sintered carbide tools,
the built-up edge is very small or nonexistent, and a smooth
machined surface results.
Conditions tending to promote the formation of built-up edges
include low cutting speed, low rake angle, high feed, and lack of
cutting fluid and large depth of cut.
Basic chip forms
Chip Breakers
Break the chips into small pieces
Control the continuous ribbon like chips that are formed at high
cutting speeds
Hard, sharp & hot - Dangerous to the operator
Types:
 Groove type
 Construction type

Step type Groove type Clamp type


© mjk

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