Chip has two surfaces 1. One is contact with the rake of the tool and has a shiny and burnished appearance caused by rubbing as the chip moves up the tool face. 2. The other is the original surface of the workpiece. It has jagged, rough appearance, caused by the shearing mechanism.
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P M agrawal
Continuous Chips
A continuous ribbon of chip produced during machining of ductile materials such as wrought iron, mild steel, copper and aluminium. Involves shearing of workpiece material to form the chip and sliding of the chip along the rake face of the cutting tool. chip formation occurs in a single plane, extending from the cutting tool to the unmachined work surface. Primary deformation zone: Area where plastic deformation of the crystal structure and hence shear occurs Shear angle: Angle on which the chip separates from the metal
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Continuous Chips
Indicates steady state cutting conditions (most research conducted under these conditions) Considered ideal for efficient cutting action because it results in better surface finish Cutting conditions: Ductile material High cutting velocity Lower feed rate Larger positive rake angle Use of cutting fluids as coolant and lubricant While machining ductile metals at high speed, chips are deliberately broken into small segments of regular size and shape by using chip breakers mainly for convenience and reduction of chip-tool contact length
2/15/2013
P M agrawal
2/15/2013
P M agrawal
Discontinuous Chips
During the formation of chip, the material undergoes severe strain. If the workpiece material is brittle, fracture will occur in the primary deformation zone when the chip is only partly formed. Under these conditions the chip separates from the unmachined portion. Cycle is repeated during the cutting operation, with the rupture of each segment occurring on the shear angle or plane. Poor surface produced due to these successive ruptures Generally, chip segments are either loosely attached to each other or totally fragmented.
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Discontinuous Chips
Cutting Conditions: Brittle metal such as cast iron and hard bronze are cut. Brittle workpiece materials lack the ductility to undergo the high shear strains and form continuous chips. Hard particles and impurities in the matrix of materials will act as stress-raisers and actively encourage chip breakage (gray cast iron having graphite flakes, inclusions of manganese sulfide in free machining steels) Very low cutting speeds (produced even if some ductile metals are cut at very low speeds and high feeds) Small or negative rake angles and heavy depth of cut
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P M agrawal
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P M agrawal
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the action of a chip breaker. Note that the chip breaker decreases the radius of curvature of the chip. b. Chip breaker clamped on the rake face of a cutting tool. c. Grooves in cutting tools acting as chip breakers
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Most modern cutting tools and inserts have built-in chipbreaker features of various design.
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