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Lec Chip Formation 17 Mar

The document discusses the mechanics of machining, focusing on important parameters such as chip thickness and cutting edge inclination. It differentiates between orthogonal and oblique cutting processes, explaining their geometric and operational characteristics. Additionally, it covers chip formation types, including continuous and discontinuous chips, and highlights the implications of ductility on machining safety and efficiency.

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2 views

Lec Chip Formation 17 Mar

The document discusses the mechanics of machining, focusing on important parameters such as chip thickness and cutting edge inclination. It differentiates between orthogonal and oblique cutting processes, explaining their geometric and operational characteristics. Additionally, it covers chip formation types, including continuous and discontinuous chips, and highlights the implications of ductility on machining safety and efficiency.

Uploaded by

navneetmanoj04
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Manufacturing Processes (ME F219)

Prof Amrita Priyadarshini


Associate Professor
Department of Mechanical
Engineering
BITS Pilani
Hyderabad Campus

Mechanics of Machining

2
Important Parameters
Parameters:
• Thickness of uncut layer, t1

• Thickness of chip, t2
• Inclination of chip tool interface, α
• Relative velocity of workpiece and tool, v

Machining operation can be represented by a 2D model when


• Work and chip move in the plane parallel to paper
• No component of velocity or motion in the direction perpendicular
to the plane of the paper
• Cutting edge is straight
• v is perpendicular to the cutting edge
BITS Pilani, Hyderabad Campus
Orthogonal vs Oblique

Orthogonal cutting process (Two Dimensional)


• In orthogonal cutting process, the cutting edge is perpendicular (90 degree) to the relative velocity.
• The chip flows in a direction normal to cutting edge of the tool. A perfectly sharp tool will cut the metal
on rake surface.
Oblique cutting process (Three Dimensional)
• In oblique cutting process, the cutting edge is inclined at an acute angle (less than 90 degree) to the
relative velocity. The chip flows sideway in a long curl.
• The chip flows in a direction at an angle with normal to the cutting edge of the tool.
Orthogonal vs Oblique Cutting
Comparative Features
Pipe turning
Mechanism of Chip Formation
Geometry of Orthogonal Machining

• Under normal machining conditions, the


thickness of shear zone is very small and can be
idealized as plane
• Shear plane: Plane OS
• Shear angle: Inclination of shear plane with
machined surface, φ
Determination of shear angle
Considering two right angle triangles SNO and QPO:

r = Cutting ratio
Determination of Shear Strain
Shear strain

ϕ ϕ
BITS Pilani, Hyderabad Campus
BITS Pilani, Hyderabad Campus
Types of chips
Continuous chips

• Ductile work materials


• High cutting speed
• High rake angles, sharp cutting edge
• Small feed and depth of cut
• Low tool chip friction
• Good surface finish
• Tend to get tangled around the tool
• Formation of very lengthy chips are
hazardous to machining process and
Failure to understand and control ductility and its
operator effects on our chips can result in safety hazards to
machine operators
Discontinuous chips
Continuous chips with BUE
• Ductile materials
• Low to medium cutting speeds
• Tool chip friction causes portions of chip to adhere to rake face
• BUE forms, then break off, cyclically

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