Mechanism of chip formation in machining process.

Presented by:
SHRADDHA SANGOLE

Content
Machining. Chip. Mechanism of chip formation. Piispanens card analogy. Direction of elongation of crystals. Types of chips.

Machining is a process of gradual removal of excess of material from the preformed blanks in the form of chips.

The portion of the material that has been cut away from the work material by the cutting tool is called the chip.

A wedge shaped tool is moved relative to the work piece. Shearing stresses is initiated in the work material. At the zone near the contact of the tool-work, the strain becomes very intense. At either side of the intense shear, the material curves around to form chip. Chip moves upward along the rake face. Continued application of force causes the material to rupture and reaches a point of plastic flow passing across the face to tool or it fractures and breaks away in the form of chips.

The formation of chip and its motion along the tool face can be visualized from an idealized model in which a stack of inclined playing cards is pushed against a tool. As the tool advances, segments which had been part of the w/p bec0me part of the chip. The card closest to the tool point slips to a finite distance. When the tool reaches the next card, the previously slipped card moves upward along the tool face as a part of chip. Thus in this way the chips are formed.

Discontinuous chips Continuous chips Continuous chip with built up edges (BUE)

I t is a series of discontinuous elements or segments. Fracture takes place above the cutting edge of the tool. It occurs when the compressive forces exceed the fracture limit of the work material.

Factors responsible : Brittle material Low cutting speed Small rake angle These chips are easily handled and disposed off. And give good surface finish.

Formed due to plastic deformation of work material. They are smooth on back face with almost uniform thickness throughout. Factors responsible: Ductile materials High cutting speed Large rake angle Cutting fluid There is low friction between chip and tool face making it more desirable. Use of chip breakers.

These chips appear in large segmented coils and not as smooth as continuous chips. Formation of built up edge. Tool edge is covered with BUE and so there is poor surface finish.

Factors responsible: Ductile materials Low cutting speed Small rake angle Insufficient cutting fluid There is high power consumption and poor surface finish. Hence undesirable.