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LM5

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Indian Institute of Technology Delhi

Manufacturing Processes - II

Module – 2 : Mechanics of Machining

Lecture – 5 : Mechanism of chip formation

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Indian Institute of Technology Delhi

Instructional objectives :
To enable the students, at the end of this lecture,
(i) describe with illustration the mechanism of
chip formation in machining
• ductile materials and
• brittle materials
(ii) describe geom. characteristics of ductile chips
• chip reduction coefficient & cutting ratio
• shear angle and cutting strain
(iii) Identify the causes, characteristics and effects
of built – up – edge (BUE) formation.
(iv) Classify chips and identify the conditions.
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Machining is characterised by gradual material


removal in the form of chips.

The form of chips is an important index of


machining as it indicates :

• nature and behavior of the work material


under machining
• specific energy requirement to machine
• nature and degree of interaction at the
work – tool interfaces.
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The form and colour of chips depend upon

• work material
• cutting tool – material and geometry
• levels of the process parameters
• application of cutting fluid

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Mechanism of chip formation in machining
ductile materials
a1: chip thickness (before cut)
a2: chip thickness (after cut)

Vf
Work

F
Tool N
R
o
VC

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Lamellar chip formation by shear

Piispanen’s model of card analogy to explain


Chip formation in ductile material
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Experimental study of chip formation
Purpose :
Experimental methods :
• study of grid deformation
• study of frozen chips
• study of running chips by high speed camera

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Chip formation in machining brittle materials

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(ii) Geom. characteristics of continuous chips


• chip reduction coefficient () & cutting ratio (r)

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Kronenberg’s model : relating  with  and 


 (  o )
 e 2

 10
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VC'

• shear angle, o a1
Shear plane

A
B

o
a2

(o - o)

O o
C

AC = a2 = OAcos(o-o) VC
o
AB = a1 = OAsino

cos  o r cos  o
tan  o  
  sin  o 1 r sin  o
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• Average cutting strain, 


s PM
 
Y ON
o
s
s

Y
O
M
o
N
P s shear strain
Y
o
PN  NM PN NM
  
ON ON ON
  cot  o  tan(  o o ) 12
Indian Institute of Technology Delhi

(iii) Built – up – edge (BUE) formation

• Causes of BUE formation


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• characteristics of BUE
Shape, size and bond strength of BUE depends on:
• work – tool materials
• tool geometry
• stress and temperature
• cutting fluid application

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• Effects of BUE formation

— unfavourable rake angle and consequences


— fluctuation in cutting forces and consequences
— poor surface finish
— may reduce tool life

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(iv)Types of chips & condns. favouring those chip forms
Type of chips conditions
Work Cutting Feed Rake CF
matl. Vel. VC so angle,
1.discont. type
• irregular absent/
size & shape Brittle
inadeq.
• regular Ductile medium large - ve
size & shape but hard
2. cont. type Duct.&soft high low + ve profuse
• without BUE
Duct. medium med. / absent/
• with BUE large inadeq
&sticky
3. Jointed type Semi low / med. / - ve abs./
ductile medium large inadeq.
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A. Quiz test
Identify the correct one out of the four given answers
1. In turning mild steel the value of  will be
(a) > 1.0
(b) < 1.0
(c) = 1.0
(d) none of the above
2. The value of shear angle, o depends upon
(a) tool rake angle
(b) friction at chip-tool interface
(c) built – up – edge formation
(d) all of the above
(contd.) 17
Indian Institute of Technology Delhi

3. Shaping grey cast iron block will produce


(a) continuous chip with BUE
(b) continuous chip without BUE
(c) discontinuous chip of irregular size & shape
(d) discontinuous chip of regular size & shape

4. The value of chip reduction coefficient,  does


not depend upon
(a) cutting velocity
(b) depth of cut
(c) cutting tool material
(d) tool rake angle
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B. Numerical problem

1. During plain turning mild steel by a tool of


geometry, 0o, 00, 8o, 7o, 15o, 90o, 0 (mm) at
so= 0.2 mm/rev, the chip thickness was found to
be 0.5 mm. Determine the values of  and o
in the above case.

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Answers
A. Quiz Test
1 – (a)
2 – (d)
3 – (c)
4 – (b)
B. Numerical Problem
a2 a2 0.5
     2.5
a1 so sin  0.2x sin 90o

cos  o cos 0o
tan  o   [   0 o
]
and   sin  o 2.5  sin 0 o o

1 1
   0 .4
 2 .5
  o  tan 1(0.4)  21.8o
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THANK YOU

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