Manufacturing Processes IM212

Dr. Mostafa Rostom

Lecture: 8
Chip formation

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Chip Formation

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 Metal cutting is a chip formation process

„ Involving:
„ Elastic deformation
„ Plastic deformation

„ Accompanied phenomena:
„ Friction
„ Heat generation
„ Built up edge formation
„ Curling and counteraction of chip
„ Work-hardening of machined surface
„ Wear of the tool
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 Metal Cutting Operation
„ The action of cutting tool subjects the layer of
metal being cut to compression, which is
accompanied by elastic and plastic deformation

stress-strain curve Slip bands in a monocrystal of tin

under tension
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 Type Of Chips
„ Discontinuous / Segmental
„ Inhomogeneous
„ Continuous
„ Fractured

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 Discontinuous Chip
„ Conditions:
„ Hard metal workpiece
„ Low ductility workpiece
„ Cutting at low cutting
speed

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Discontinuous Chip Formation Process

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Photos of discontinuous chip formation

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Shear surface and slip plan

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 Inhomogeneous Strain Chips
„ Conditions:
„ Ductile material workpiece
„ Medium cutting speed

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 Continuous Chips
„ Conditions:
„ Ductile material workpiece
„ High toughness workpiece
„ Smaller cutting angle
„ Small depth of cut
„ Good oiliness
„ High cutting speed

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Continuous Chip Formation

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 Fractured Chips
„ They are obtained in machining of low plasticity
(hard cast iron, hard bronze, etc.)
„ Crack propagation is the main cutting
mechanism
„ Degrade surface finish

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Arrested Layer

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 Built Up Edge (BUE)
„ It is a wedge-shape, consists of a part of the
workpiece material, which is heavily deformed,
stagnant on the tool face and frequently
adheres to the tool

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 BUE Drawbacks
„ Source of vibration
„ Degrading surface finish
„ Inaccuracies in workpiece dimensions
„ Increasing tool wear
„ Flank wear
„ Adhesion wear
„ Crater wear

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 Factors Affecting BUE
„ Tool face smoothness
„ Cutting fluids
„ Rake angle
„ Tool-workpiece weldability
„ Workpiece material
„ Pressure
„ Temperature

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Effect of Cutting Speed on BUE Height

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 Curling
„ Sources
„ Larger deformation of the chip layer adjoining the
tool face
„ Sharp direction changes due to BUE
„ Non uniform cooling of chip along its thickness

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 Chip curl types
„ Flat logarithmic spiral
„ Formed in orthogonal cutting such
as parting off
„ Approach angle, ϕ = 90° & Cutting
edge inclination, λ = 0°

„ Helix
„ Formed if ϕ ≠ 90° and λ ≠ 0°
„ Formed in complex cutting

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 Factors Influence Chip Curling
„ Rake angle
„ Height of BUE
„ Thickness on uncut chip (feed)
„ Cutting fluid
„ Depth of wear crater
„ Cutting speed

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Effect of the Depth of Wear Crater

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Effect of Cutting Speed

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 Effects of Chip Curling
„ Hazards to machine tool operators
„ Interferes watching of the workpiece
„ Winds up on the workpiece
„ Entangles the workpiece and carriage
„ Fills the chip space or flutes of multi edge
tools such as broaches and milling cutters

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Curling Elimination by Chip Breaker

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 Chip Contraction
„ The chip turns out to be shorter due to plastic
compression (L < Lo).
„ Longitudinal chip contraction is the decreasing of the
chip length
„ Transverse contraction is the increasing of the chip
thickness
„ Coefficient of contraction
(cutting ratio)
k = Lo / L = f / fo > 1

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 Motivations of Chip Contraction Studying

„ Measure of the degree of plastic

deformation
„ Measure to cutting force
„ Measure to cutting power

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 Factors Affecting Chip Contraction

„ Tool geometry
„ Rake angle Nose radius

„ Cutting variables
„ Cutting speed Feed rate

„ Cutting fluid

„ Workpiece material
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Effect of the rake angle

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Effect of the nose radius

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Effect Of Cutting Speed and Uncut
Chip Thickness

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 Work Hardening
„ It is the increasing of the workpiece
surface hardness due to plastic
deformation

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Microhardness distribution

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 Influences of Work Hardening
„ Increase workpiece surface microhardness
„ Increase wear resistance
„ Increase endurance strength

„ Decrease the resistance to impact loads

„ Degrades the workpiece surface quality by
imprinting hard particles
„ Affects the subsequent machining operations

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Classification of chips in ISO Draft Standard

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