Program : Bachelor in Mechanical Engineering (Hons.

Course : Manufacturing and Technology Processes Lab

Code : MEM 564

TITLE

Study of Chip Formation

PROGRAMME OUTCOMES (PO)

Programme Outcomes Details

PO1 Ability to acquire and apply knowledge of engineering
fundamental
PO2 Ability to communicate effectively, not only with engineers
but also with community at large.
PO3 Having in depth technical competence in a specific
engineering discipline
PO4 Ability to undertake problem identification, formulation and
solution creatively
PO6 Ability to function effectively as an individual and in a group
with a capacity to be a leader or manager as well as an
effective team member.
PO8 Recognizing the need to undertake lifelong learning, having
entrepreneurship vision and possessing/acquiring the capacity
to do so.
PO9 Ability to design and conduct experiments, as well as to
analyze and interpret data

OBJECTIVE

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The objective of this report is to illustrate various types of chip that can be produced during
metal cutting process, the condition for each type and how they look like. Besides that, we
have to examine the effect of lubrication on chip formation.

INTRODUCTION

In the metal cutting process, layers from metal are removed systematically from a work piece
by the action of the cutting tool. The metal removed referred as chips. Basically, the chip
produced in the different formed sizes due to various conditions. The type of chip produced
depends on the work and tools materials, the geometry and the speed of the cutting process
and the existence or absence of lubrication. Knowing about chip formation and control is
very important because among others, it affect tool life, surface finish of type product,
disposal problem and also cost. Roundly, different chip formed different quality of surface
finish and tolerance.

There are three types of chip:

1) Continuous chip

Continuous chips are usually formed while machining ductile material such as mild
steel, iron, copper and aluminum at high cutting speed and/or high rakes angles. The
deformation takes place along a narrow shear zone, the primary shear zone. Caused by
friction, the chip develop secondary shear zone at the tool-chip interface. The secondary
zone becomes deeper as tool-chip friction increase. Although they generally produce
good surface finish, continuous chips are always desirable, particularly in automated
machine tools. This problem can be overcome by the use of chip-breakers; a device
clamped to the top of the tool that encourages the chip to curl more tightly, hitting the
work piece and breaking off.

2) Continuous chip with a built-up-age

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 A built-up edge (BUE), consisting of layers of material from the workpiece that are
gradually deposited on the tool (additional molten material sticking to it) and may form at
the tip of the tool during cutting. BUE.s can effect change the geometry of the cutting
edge and the rough surface finish produced. Condition for BUE formation:

 Mating metals must be mixable with each other.

 Metallic bonding.
 High temperature.
 Ductile materials and high stresses.
 Velocity must be low.
The tendency for BUE reduced by any following practices:

 Decreasing the depth of cut.

 Increasing the rake angle.
 Using a sharp cutting tool.
 Using an effective cutting tool.

3) Discontinuous chip

This is formed in small segments separately due to periodic rupture ahead of the
cutting tool due to high stress applied by the cutting tool. Discontinuous chip usually
form under the following condition:

 Brittle workpiece material, because they do not have the capacity to undergo
the high shear strains involved in cutting.
 Workpiece materials that contain hard inclusions and impurities, or have
structures such as the graphite flakes in gray cast iron.
 Large depth of cut.
 Low rakes angles.
 Lack of an effective cutting fluid.
 Low stiffness of the machine tool.

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EQUIPMENT

Lathe machine, work piece material, cutting tools, cutting fluids, etc.

OPERATION PROCEDURE

1) The lecturer briefing about lathe machine and types of chip formation
2) The expert machinist do the demonstration by varying the cutting speed, feed rate, and
the usage of the cutting fluid or coolant.
3) The machine carried out two situations, with coolant and without coolant.
4) For each single variation of the discussed parameter, the chips formed were taken out and
put on the table for clearer observation of the type of chips formed.
5) Discussion into group for each chip formed.

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RESULTS

Cutting Feed Rate Depth of Chip Formation

Speed Cut
(RPM) (D.O.C) With Coolent Without Coolent
(mm)
130 0.1 2

Discontinuous, silver, Discontinuous, silver

short with little burn, short
790 0.2 1

Continuous, silver, long Continuous. silver, long

200 1.0 2

Discontinuous, black, Continuous, blue, long

short (built up age) (built up age)
1200 0.04 3

Continuous, silver, long Continuous, blue, long

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DISCUSSION

1. Discuss the result of the demonstration.

Cutting Feed Depth of Observation

Speed Rate Cut
(RPM) (D.O.C)
(mm)
130 0.1 2 From the observation, the chip that been produce
is discontinuous due to low cutting speed and
high feed rate. There are differences between
using cutting fluid and not using cutting fluid.
Without using cutting fluid, the chips colour is
become little dark that chips colour with cutting
fluid. This due to the high cutting temperature.
790 0.2 1 From the observation, the chip that been produce
is continuous due to high cutting speed and fine
feed rate. Without using cutting fluid, the chips
colour is become little dark that chips colour with
cutting fluid. This due to the high cutting
temperature.

200 1.0 2 From the observation, the chip that been produce
is discontinuous and short with built up age
because of low cutting fluid, high temperature
cutting process due to friction and high feed rate
with cutting fluid. The chip colour is black.

The chip formation without cutting fluid is

continuous, long and also with built up age due to
low cutting speed and high feed rate. the chip
colour become more darker.
1200 0.04 3 From observation, the chip formation is
continuous chip because the high cutting speed,
fine feed rate. The differences between chip
formation with and without cutting fluid only the

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 colour, the chip that not use coolant is darker that
use coolant.

2. Why the knowledge on chip formation is very important in metal cutting.

Knowledge of chip formation in metal cutting is very important because from

the chip that formed from the machine, we can see whether the parameter like feed
rate, cutting speed, depth of cut and cooling fluid that being set is suitable or not with
the workpiece and cutting tools. The type of chip that was produced by machine
depends on the work and tool materials.

Chip formation also affects the surface finishing of the workpiece, commonly
continuous chips produce good and better surface finish while discontinuous chips
produce bad surface finishing.

Knowledge of chips formation also important because it affects the tools life,
safety factor, cost and many more. Long continuous chips will damage the machine
tools and also even hurt the machinist that operates the machine. At the same time, the
operating cost also will also increase because tools machine need to be replaced many
time. That why the knowledge of chip formation is important to make sure that thing
mention above not happen.

3. The trend in machining now is dry machining. Explain / give reasons why.

Dry machining is machining processes that not use any cutting fluid or called
also as coolant. Dry machining also known as green machining. Nowadays, everyone
talks about green technology that can save environment, same as the dry machining
here. Dry machining also help in save the environment by reduce the using of cutting
fluid. From survey that has been conducted in European country, approximately 800
tonnes of the used cutting fluid has to be process and dispose last year. That is very
harmful to environment.

Dry machining is a trend because it cut the cost of manufacturing process

compared to machining that use cutting fluid. The cost of management and dispose
the used cutting fluid is very expensive. About 16 percent of the manufacturing cost is
spending to manage the used cutting fluid and dispose it.

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 Another reason why dry machining becomes trend is much material like to
stay dry like aluminium, cast iron and alloys. This type of material is easy to cut with
the dry machining because the relative cutting temperature is low. Example of dry
machining machine is like drilling machine.

4. Comment on the various chuck used by lathe machines.

Chucks are used to grip the workpiece. There are 2 various chuck used in lathe
machining that is three jaws and four jaws. Three jaws universal chuck is used to hold
the round and hexagonal bar or other symmetrical work. Three jaws chuck can be
divided into two categories that are life jaws and death jaws. All jaws move together
call the life jaws. The jaws can clamp the outside or inside the work piece.

Other type of chuck is four jaws chuck. Used to hold the square, octagonal and
also can be used ti clamp the irregular workpiece or odd shape of the workpiece. This
types of jaws is very important to centre the workpiece and to make sure securely to
heavy feeds and depth of cuts.

5. Give three important accuracy aspects/procedures in metal cutting process.

The important aspects that important such as cutting speed, feed rate, depth of
cut must be suitable to each other in other to good cutting action. The position of the
workpiece must be in the correct coordinates to obtain the precise cutting process. We
must always use coolant to avoid any unwanted burning effects and colour on the
workpiece itself.

6. Discuss/give three ways for you to manage chips efficiently.

In order to manage the chips efficiently, the cutting tools and the material of
the workpiece must be chosen properly. The material must be easily cut by the cutting
tools to avoid the cutting tools become blunt and disable. After that the cutting speed
and the feed rate of the machine must be fit to each other to avoid built up age and
long chips. Built up age chips will cause the cutting tools become blunt and long chips
bring dangerous impact to the user and the machine itself. The process of lubrication
must be done to avoid the surface of workpiece become burn and black in colour.

CONCLUSION

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 As a conclusion for the study of the chips formation which are continuous,
discontinuous, and built up age chips. The formation of the chips depend on the cutting
speed, feed rate, cutting speed and cutting fluid. The cutting fluid is a big factor to the chip
formation where if the cutting process is done without the cutting fluid, the chip results in
blue and black colour. This show that cutting fluid have many effects on chip formation.

REFERENCES

1. Serope Kalpakjian and Steven R. Schmid, Manufacturing Engineering and

Technology, 4th Edition, Prentice Hall, 2001
2. Mohd Yusuff bin Haji Mohd al-Rangi, Manufacturing Process, 2003
3. Amstead, B.H., et al., Manufacturing Processes, 8th Edition, Wiley, New York