Manufacturing Process

Types of Chips
 CHIP FORMATION
• The cutting tool removes the metal from the
workpiece in the form of “chips”.
• As the tool advances into the workpiece, the metal
in front of the tool is compressed and when the
compression limit of the metal has been exceeded, it
is separated from the workpiece and flows
plastically in the form of chip.
• The plastic flow of the metal takes place in a
localised region called shear plane, which extends
from the cutting edge obliquely upto the uncut
surface in front of the tool.
 CHIP FORMATION
• Because of the relative motion between the tool
and the workpiece, material ahead of the tool
face (rake face) is compressed (elastically and
then plastically).
• Further, movement of the tool into the
workpiece deforms the work material plastically
and finally separates the deformed material from
the workpiece.
• This separated material flows on the rake face of
the tool called as chip .
THEORY OF CHIP FORMATION
THEORY OF CHIP FORMATION
 CHIP FORMATION
• The chip is formed by shear deformation (primary
shear) along a plane called the shear plane, which is
oriented at an angle Ø with the surface of the work.
• Another shearing action occurs in the chip after it
has been formed.
• This additional shear is referred to as secondary
shear to distinguish it from primary shear.
• Secondary shear results from friction between the
chip and the tool as the chip slides along the rake
face of the tool.
THEORY OF CHIP FORMATION
 THEORY OF CHIP FORMATION
• During cutting, the cutting edge of the tool is
positioned a certain distance below the original
work surface.
• This corresponds to the thickness of the chip
prior to chip formation, to.
• As the chip is formed along the shear plane, its
thickness increases to tc.
THEORY OF CHIP FORMATION
 THEORY OF CHIP FORMATION
• The ratio of to to tc is called the chip thickness
ratio (or simply the chip ratio) r.

to
r =
tc
• Since the chip thickness after cutting is always
greater than the corresponding thickness before
cutting, the chip ratio will always be less than 1.0.
 TYPES OF CHIPS
• Chip is a small piece of material removed in the
course of chopping, cutting, or breaking
something, esp. a hard material such as wood ,
stone or metal.
• In a metal cutting operation chips are separated
from the workpiece to impart the required size
and shape to the workpiece.
 TYPES OF CHIPS
• The chips that are formed during metal cutting
operations can be classified into three types:
1. Discontinuous or segmental chips
2. Continuous chips
3. Continuous chips with built-up edge.
 DISCONTINOUS CHIP
• Brittle work materials
• Low cutting speeds
• Large feed and depth of
cut
• High tool-chip friction
• Low or Negative rake
angle
 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.
• ŠIn this type the deformed material instead of
flowing continuously gets ruptured periodically.
• Discontinuous chips are easier from the chip
disposal view point.
 DISCONTINUOUS CHIP
• Also they generally provide better surface finish
(for brittle material only).
• ŠHowever, in case of ductile materials they cause
poor surface finish and low tool life.
• A discontinuous chip comes off as small chunks
or particles. When we get this chip it may
indicate:
– brittle work material
– small or negative rake angles
– large feed, depth of cut and low cutting speed
 CONTINUOUS CHIP
• Ductile work materials
• High cutting speeds
• Small feeds and depths
• Sharp cutting edge
• Low tool-chip friction
• High or Positive rake
angle
 CONTINUOUS CHIP
• Continuous chips are normally produced when
machining steel or ductile metals at high cutting
speeds.
• The continuous chip which is like a ribbon flows
along the rake face.
• ŠContinuous chip is possible because of the
ductility of metal.
CONTINUOUS CHIP
 CONTINUOUS CHIP
• It can be assumed that each layer of metal flows
along the slip plane till it is stopped by work
hardening.
• ŠEach of these layers get welded to the previous
ones because of the high temperature, thus
forming a continuous chip.
 CONTINUOUS CHIP
• Some ideal conditions that promote continuous
chips in metal cutting are:
– sharp cutting edge,
– small chip thickness (fine feed),
– large rake angle,
– high cutting speed,
– ductile work materials and
– less friction between chip tool interface through
efficient lubrication.
 CONTINUOUS CHIP
• This is the most desirable form of chip since the
surface finish obtained is good and cutting is
smooth.
• ŠIt also helps in having higher tool life and lower
power consumption.
• However, long continuous chips (as in turning)
can cause problems with regard to chip disposal.
 CONTINUOUS CHIP
• These chips also cause a hazard to the machine
operator and the workpart finish, and they
interfere with automatic operation of the turning
process.
• To help in this direction various forms of chip
breakers are frequently used with single-point
tools to force the chips to curl more tightly than
they would naturally do, thus causing them to be
broken into small pieces so that they can be
easily disposed off.
 GROOVE-TYPE CHIP BREAKER
• Groove-type chip breaker designed into the
cutting tool itself.
OBSTRUCTION-TYPE CHIP BREAKER
• Obstruction-type chip breaker designed as an
additional device on the rake face of the tool.
CONTINUOUS CHIP WITH BUILT-UP EDGE

• 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
CONTINUOUS CHIP WITH BUILT-UP EDGE
• When machining ductile materials at low-to-
medium cutting speeds, friction between tool
and chip tends to cause portions of the work
material to adhere to the rake face of the tool
near the cutting edge.
• This formation is called a built-up edge (BUE).
• The formation of a BUE is cyclical; it forms and
grows, then becomes unstable and breaks off.
CONTINUOUS CHIP WITH BUILT-UP EDGE
• Much of the detached BUE is carried away with
the chip, sometimes taking portions of the tool
rake face with it, which reduces the life of the
cutting tool.
• Portions of the detached BUE that are not
carried off with the chip become imbedded in
the newly created work surface, causing the
surface to become rough.