Machining Chip Formation, Cutting Fluids,

Vibration,, Chatter
ver. 1

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

Overview

Chip formation
Chip breaking
Cutting fluids
Vib ti and
Vibration
d chatter
h tt

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

Chip Types
Basic types of chips
and their
photomicrographs
produced in metal
cutting: (a) continuous
chip with narrow,
straight primary shear
zone; (b) secondary
shear zone at the
chip-tool interface; (c)
continuous chip with
large primary shear
zone; (d) continuous
chip with built-up
edge; (e) segmented
or nonhomogeneous
chip and (f)
discontinuous chip.
Source: After M. C.
Shaw, P. K. Wright,
and S. Kalpakjian.

(a)

(d)

(b)

(c)

(e)

(f)

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

Chip Types
(a) Continuous chip with narrow primary
shear zone
ductile materials at high speed
bad
b d ffor automation
t
ti (use
(
chip
hi b
breakers)
k )

(b) Secondary shear zone at chip-tool

interface
increased energy dissipation

(c) Continuous chip with built up edge (BUE)

hi
high
h plastic
l ti working
ki
bad for automation

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

Chip Types
(d) Continuous chip with large primary shear
zone
soft metals at low speeds and low rake angles
poor surface finish
residual stresses

(e) Segmented chip

low thermal conductivity materials

(f) Discontinuous chip

low ductility materials and/or negative rake angles
good for automation
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

Chip
p Formation

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

Chip Formation - AISI 4340

< 50

50-100
50
100

100-200
100
200

onset at
400

onset
> 800

> 3200
SFPM

Discontinuous
Built-up
edge

Continuous
Chip

Catastrophic
shear
Shear
Complete
localized
separation
chip
hi

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

Low speeds and rake anglesDiscontinuous chips

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

Discontinuous chip formation

chip
flow along
shear plane

crack
lateral deformation
following a crack
cutting
tti ttooll

workpiece

crack

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

AISI 4340: V< 50 SFPM

Discontinuous chips
L
Low
d
ductility
ili
Low T
Fracture
Chip segments
chip fracture

Result:
shock loading to tool
cracks extend into workpiece
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

10

Formation of Built
Built-up
up Edge (BUE)

chip
BUE

BUE
deposit
cutting tool

BUE
deposit
workpiece
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

11

AISI 4340: 50-100

50 100 SFPM
Built-up edge (BUE) forms
400oC max for BUE
Surface debris
sheds
h d
welds onto workpiece

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

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Continuous chips

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

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AISI 4340: 100-200

100 200 SFPM
Continuous chip
Uniform deformation over chip volume
fine scale

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

14

Further increasing speedContraction of BUE

BUE
deposit

chip

cutting tool

BUE

BUE
deposit
workpiece
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

15

Higher speeds Segmented chip

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

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AISI 4340: onset at 400 SFPM

Shear
Sh
llocalized
li d chip
hi
bands of high deformation and little
d f
deformation
ti

Essentially a thermo-plastic instability

as deformation occurs, T increases
shear strength decreases
(positive feedback system)

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

17

Card Model of Segmented

Chip Formation
chip
cutting tool

shear zone

workpiece
p

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

18

AISI 4340: Onset at > 800 SFPM

Catastrophic shear
Ti ideal model - at all speeds
low thermal conductivity and heat capacity
softens rapidly with temp

Extreme localization
Actual separation of
segments
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

19

AISI 4340: >3200 SFPM

Complete separation

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

20

BUE formation

discontinuous
BUE
surface
increases
finish
( )
(m)
cracks

BUE
contracts

into
workpiece
p

chemical
dissolution

cutting speed
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

21

Mitigation of BUE
Increased chip-tool
chip tool interface temp
Increased speed
Decreased feed
Increased ambient temperature
Increased rake angle
Improved
p o ed cchip-tool
p oo friction
c o conditions
co d o s
lubrication - internal or external
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

22

Benefits of BUE
If it can be produced to be stable,
Then it can reduce tool wear
wear.

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

23

Chip
C
p Cu
Curl

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

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Chip
p Curl
ro

ro
2

r
A
3

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

25

Chip
p Breaking
g
If you decrease the radius of chip
enoughyou can break the chip.
y
p
Why break the chip?
easier to remove chips
chips.
chips dont nest and entangle
partt or machine.
hi

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

26

Chip Breaker
chip breaker

chip
hi
shear zone

cutting tool

workpiece

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

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Integral Chip Breakers

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

28

Cutting Fluids - Effects

Reduce friction and wear
improve tool life, surface finish

Cool cutting zone

reduce temperature and distortion

Wash chips away

Prevent corrosion
Reduces forces and energy
consumption
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

29

Cutting Fluids - Types

Water based
contain salts or
soluble oils

Mineral-oil based
Synthetic

Bio-degradable
Bio-resistant
Soaps
Defoamers
Sulphur
Chlorinated

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

30

Cutting Fluids Application Methods

Brush
manual

Mist
mostly water based coolants

Flood

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

31

Coolant or Lubricant?

Temperature
Cutting speed
Type of machining operation
M th d off application
Method
li ti
brush (manual)
mist
flood
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

32

Vibration
Forced
periodic applied force
from a motor or gear drive

Self-excited
interaction
i
i off d
dynamics
i off chip
hi removall
process and structural dynamics of
machine tool

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

33

Chatter
Results from vibration
Tool
T lb
bounces iin and
d outt off th
the
workpiece

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

34

Glacial Chatter

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

35

Chatter Types
Regenerative (f < 1000 Hz)
when a surface undulation
previously produced causes a
cutting force variation

Coupling (f < 1000 Hz)

two modes of tool or machine
vibration are coupled (x and y
directions)
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

36

Chatter Types
Self-excited vibration (1000 < f < 10,000 Hz)
negative slope of the shear-stress
shear stress vs.
temperature ( vs. ) relationship
force components
p
p
provide p
positive instead
of negative damping

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

37

Vibration Elimination

Stiffer machines
Tuned dampers
Active control
Support workpiece rigidly
Mi i i cutter
Minimize
tt overhang
h
Modify tool and cutter geometry
Change process parameters
speed,
p
, feed,, depth
p of cut,, cutting
g fluid
ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

38

Summary
Chip formation process
Cutting fluids
Vibration and chatter

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

39

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

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