CONTENTS

Page No: Marks Marks PO Achievement Remarks

Allocated Obtained
FRONT COVER
GRADING FORM

CONTENTS Page 1
1. Title Page 2
2. Objective(s) Page 2 5 PO1
3. Introduction (background and Page 2 - 10 (Total Marks:20)
theory) 5
4. Apparatus Page 6 5
5. Experimental Procedure Page 7 10 PO3
6. Results & Data Analysis Page 8 20 (Total Marks: 30)

7. Discussion of Results Page 9 15 PO2

-13 (Total Marks: 30)
8. Conclusion Page 14 8
9. Recommendation Page 14 5
10. References Page 15 2
11. Group Members Page 15 20 PO6
Contribution (Total Marks:20)
1.0 Title: Study of Chip Formation

2.0 Abstract:
This report is about the investigation or experiment of physical phenomena of chip
formation during metal cutting process. Besides that, this experiment also done to
examine the effect of lubrication on chip formation. The study concerns the
machining of work piece material which is mild steel with cutting tool of carbide.
This study focuses on comparing multiple type of chip formation produced by
different of cutting speed, depth of cut, feed rate and the presence of coolant. The
present work deals with experimental investigation in the role of coolant on chip
formation like chip shape and color in plain turning of medium mild steel rod at
different cutting velocities and feed rates.

3.0 Objective:
 To illustrate the various types of chips that can be produced during metal cutting
process.
 To examine the effect of lubrication on chip formation.

4.0 Introduction:
The chip formation process is the same for most machining processes, and it has
been researched in order to determine closed-form solutions for speeds, feeds, and
other parameters which have in the past been determined by the "feel" of the
machinist. 
 
With CNC machine tools producing parts at ever-faster rates, it has become
important to provide automatic algorithms for determining speeds and feeds. The
information presented in this section are some of the more important aspects of
chip formation. Reasons for machining being difficult to analyze and characterize
can be summarized as follows:

 The strain rate is extremely high compared to that of other fabrication processes.
 The process varies considerably depending on the part material, temperature,
cutting fluids, etc.
 The process varies considerably depending on the tool material, temperature,
chatter and vibration, etc.
 The process is only constrained by the tool cutter. Unlike other processes such
as molding and cold forming which are contained, a lot of variation can occur
even with the same configuration.
4.1 Chip Formation Theory

Below is illustrated the basic geometry of two-dimensional chip formation. The

model is two-dimensional for simplicity.

Figure 1 : Basic Geometry of 2-D Chip Formation

 
The material immediately in front of the tool is bent upward and is compressed in a
narrow zone of shear which is shaded on the drawing above. For most analyses,
this shear area can be simplified to a plane.
 
As the tool moves forward, the material ahead of the tool passes through this shear
plane. If the material is ductile, fracture will not occur and the chip will be in the form
of a continuous ribbon. If the material is brittle, the chip will periodically fracture and
separate chips will be formed. It is within the shear zone that gross deformation of
the material takes place which allows the chips to be removed. As on the stress-
strain diagram of a metal, the elastic deformation is followed by plastic deformation.
The material ultimately must yield in shear. 

 
 The figure below depicts the cutting area in terms of lines of flow. As the material
flows from the bulk of the work piece to the shear area, it is violently sheared, and
then continues into the chip section.

Figure 2 : The Cutting Area

In metal cutting process, layers of metal are removed systematically from a work
piece by the action of the cutting tool. The piece of metal removed is referred to as
chips and the chips produced are in the different forms and sizes due to various
conditions. In practice, it is possible to produce three distinct types of chip namely
as:

a) Continuous chips

 It usually formed when machined at high cutting speed

and high rake angle. Also in sharp cutting edge and less
friction

 Typical for ductile material such as mill, steel, copper,

aluminum and other.

 Chip disposal is a problem because at the large coils of chips. It can be solve
using chip breakers (to follow) or by changing parameters like cutting speed,
feed, depth of cut and by using cutting fluids.
b) Discontinuous chips

 It usually formed by very low or very high cutting speed, large

depth of cut, low rate angles, lack of an effective cutting fluid and
low stiffness of the tool holders

 Typical for brittle material. Work piece materials that contain hard
inclusions and impurities or have structured such as the graphite flakes in
gray cast iron.

 The problem is machine tool may begin to vibrate and chatter. The stiffness of
the cutting tool holder, the work holding device and the machine tool are
important in cutting with serrated chip as well as discontinuous chips.

) Continuous chip with build up edge (BUE)

 As it grows larger, the BUE becomes unstable and eventually breaks apart.
Cycle of BUE formation and destruction is repeated
continuously during the cutting operation until correction
measures are taken.

 Typical of ductile material such as cast iron.

In effect, BUE changes the geometry of the cutting edge and dulls it. It is major
factor that adversely affects surface finish. It can solve by increase the cutting
speed, decrease depth of cut, increase the rake angle and use the sharp tools.
5.0 Apparatus:

Equipments Function
1) Lathe machine - As a machine tool and equipped
with individual electric motors.

- Use a rod of mild steel.

2) Work piece material

- Use carbide because their high

3) Cutting tool hardness, high elastic modulus,
and low thermal expansion.
- To reduce friction and wear, cool
4) Cutting fluid the cutting zone, and flash away
the chips from cutting zone.
- To use for measure the
5) Vernier caliper dimensions of work piece.

Table 1 : Equipment and Function

6.0 Procedure:

1. The lathe machine was set up by the instructor.

2. The demonstration of cutting was demonstrated by the instructor and the relevant
parameters are been distinguish.
3. The relevant parameters in this demonstration are cutting speed, feed rate, and
the usage of cutting fluid.
4. First, the cutting machine was set up at 130 rpm speed, 3mm of depth of cutting,
and 0.25 of feed rate and in the existence of coolant. After that, the experiment
with same parameters however in the absence of coolant.
5. Second, the cutting machine was set up at 130 rpm speed, 3mm of depth of
cutting, and 1.0 of feed rate and in the existence of coolant. After that, the
experiment with same parameters however in the absence of coolant.
6. Thirdly, the cutting machine was set up at 1200 rpm speed, 3mm of depth of
cutting, and 0.05 of feed rate and in the existence of coolant. After that, the
experiment with same parameters however in the absence of coolant.
7. For every state of experiment, the shape and color of chip produced after the
cutting process recorded.
7.0 Result Observation:
With Coolant Without Coolant

Cutting Speed: 300 rpm Cutting Speed: 300 rpm

Feed Rate: 0.2 mm/rev Feed Rate: 0.2 mm/rev
Depth of Cut: 2mm Depth of Cut: 2mm
Color: Silver Color: Silver + Yellow

Cutting Speed: 1200 rpm Cutting Speed: 1200 rpm

Feed Rate: 0.05 mm/rev Feed Rate: 0.05 mm/rev
Depth of Cut: 2mm Depth of Cut: 2mm
Color: Yellow Color: Yellow + Purple

Cutting Speed: 130 rpm Cutting Speed: 130 rpm

Feed Rate: 1.0 mm/rev Feed Rate : 1.0 mm/rev
Depth of Cut: 2mm Depth of Cut: 2mm
Color: Gold Color: Burning Brown
8.0 Discussion:
1) Discuss the result of the demonstration.

From the formation of chips, it showed that chips produced at the existence of
coolant are silver color and the surface is smoother. However, in the absence of
coolant, chips that produced are brown color. These showed that the use of lubrication
can affect surface finishing of the work piece.

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

The knowledge of chip formation is very important in metal cutting because it can
helps to understand the characteristics of chips and to attain favorable chip forms. The
form of the chips is an important index of machining because it directly or indirectly
indicates the nature and behavior of the work material under machining condition.
Besides that, it gave the specific energy requirement (amount of energy required to
remove unit volume of work material) in the machining work. Other than that, nature and
degree of interaction at the chip-tool interfaces.

3) The trend in machining now is dry machining. Explain and give reason why.

Dry Machining term refers to machining process without the presence of coolants
fluids.
There are the reasons to use dry machining:
a) Nowadays, most technologies are high speed machining. So, no need to use
coolant.
b) One of the main factors is that coolants usage consumes the cost of more than 5
times compared to the cost of cutting tools. In engineering field, this is a
tremendously expensive.
c) Dry machining would also result in more environmentally-friendly clean-up of
workpieces, as no oil would have adhered to the workpiece.
d) Since there is no coolant being used in the process, the cutting tool must be able to
withstand the high temperature. Thus, both ordinary tools and coated tools are used
in dry machining.
e) Lastly, it can eliminate production shutdown for machinery clean-up.

Figure
Figure3ss4 : Ultra-high-speed in
Figure 3 : Dry Machining
Dry Machining
4) Comment on the various chuck used by the lathe machines.

Workholding devices are particularly important in machine tools and machining

operations. Chuck is one of the work holding devices in lathe machine. The function is
to grip the job or workpiece. Chucks is located at the spindle axis of the lathe machine.
This arrangement provides convenience in that parts can be mounted and dismounted
quickly. There are many types of chucks being used in lathe machine, each has specific
purpose and method of clamping work piece.

a) Three-jaw universal chucks – It used to hold round or hexagonal bar or other

symmetrical work. All jaws move together. The jaws may clamp outside or inside the
workpiece, depending on convenience and the operation to be performed. The job is
held in such a way that its axis coincides with that of lathe spindle.

b) Four-jaw independent chucks – It used for square or octagonal work. The jaws
move independently of each other. This type of chuck is also useful for irregular
work wherein a hole is to be positioned off centre on the workpiece.

c) Combination chuck – It combines the features of both the above mentioned

chucks. It is a four jaw chuck in which the jaws may be moved separately or
together.

d) Power chucks – It is actuated either hydraulically or pneumatically. It often is used

in automated manufacturing process, high production rates, and also robotic work
piece handling.

Figure 5 : Three-jaw Universal Figure 6 : Four-jaw Independent

Chucks Chucks

5) Give three important

accuracy Figure 4 : Power Chucks
aspects/procedures in metal
cutting process.
 1. Reduced vibrations
If the motion repeats itself after given interval of time, the motion is known as
vibration. Vibration, in general is a form of wasted energy and undesirable in
many cases. Uncontrolled vibration can result in the following;

a) Poor surface finish

b) Loss dimensional accuracy of the workpiece
c) Shorter tool life; premature wear, chipping and failure of the cutting
tool, a crucial possible damage to the machine tool components
from excessive vibration
d) Objectionable or unpleasant noise.
Because of that, vibrations should be reduced such us with minimize tool
overhang and improve the damping capacity of the machine tool to achieve the
good result on product and machine.

2. Accuracy and repeatability of part size

The big change in the last decade or so is that producers want to shift the
attainment of this accuracy as far up the line as possible, to the cutting stage.
This can often remove the need for subsequent processing. Putting more
accuracy into the cutting process is a trend that is likely to continue. However the
costs must be balanced against the benefit that greater and greater accuracy will
deliver. These benefits will peak at a certain point and thereafter, for every penny
spent on attaining more accuracy, the return on that investment will reduce.

3. Position of the cutting tool – Oblique cutting.

Position of the cutting tool must in right position to get the good accuracy.
The good cutting process is oblique cutting. Oblique cutting is more advantages
than orthogonal cutting at same feed rate and depth of cut because the force of
oblique cutting acts larger area of the tool. This will result in longer tool life and
can remove more material. This in turn translates to better economy and
productivity.

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

1. Collecting chips systematically

The chips produced during machining must be collected and dispose of properly.
The volume of chip produced can very high, particularly in high speed and high-
removal-rate operation. The chip management is a process involves collecting
chips from their source in the machine tool in an efficient manner and removing
them from the work area. Chip can be collected by any of the following methods:

 Allowing gravity to drop them on a steel conveyor belt

 Dragging the chips from a settling tank
 Using augers, with feed screws similar to those in meat grinders
 Using magnetic conveyors (for ferrous chips)
 Employing vacuum methods of removal
The collected chips may be recycled or dumped (provided they are free of
harmful chemical component or fluids).

2. Cutting Fluid & Lubricant

The aims in metal cutting are to retain accuracy, to get a good surface finish on
the workpiece and at the same time to have a longer tool life. However during the
metal cutting process heat is generated due to the deformation of the material
ahead of the tool and friction at the tool point Heat generated due to friction can
readily be reduced by using a lubricant. Heat caused by deformation cannot be
reduced and yet it can be carried away by a fluid. Thus the use of a cutting fluid
will serve to reduce the tool wear, give better surface finish and a tighter
dimensional control. The proper selection, mixing and application of cutting fluids
is however often misunderstood and frequently neglected in machining practice.
In order that the cutting fluid performs its functions properly it is necessary to
ensure that the cutting fluid be applied directly to the cutting zone so that it can
form a film at the sliding surfaces of the tool.

3. Cutting Speed & Feed

 The relative `speed' of work piece rotation and `feed' rates of the cutting tool
coupled to the material to be cut must be given your serious attention. This
relationship is of paramount importance if items are to be manufactured in a cost-
effective way in the minimum time, in accordance with the laid down
specifications for quality of surface finish and accuracy. We, as a potential
supervisory / management level engineer, must take particular note of these
important parameters and ensure that you gain a fundamental understanding of
factors involved. All materials have an optimum Cutting Speed and it is defined
as the speed at which a point on the surface of the work passes the cutting edge
or point of the tool and is normally given in meters/min. The term `feed' is used to
describe the distance the tool moves per revolution of the workpiece and
depends largely on the surface finish required. For roughing out a soft material a
feed of up to 0.25 mm per revolution may be used. With tougher materials this
should be reduced to a maximum of 0.10 mm/rev. Finishing requires a finer feed
then what is recommended

Conclusion:
From the observation which has been made during the demonstration, it can be
concluded that the formation of the chips were depends on the several parameters such
as; speed, feed rate, type of material, depth of cut, usage of cutting fluid and several
more. Basically there were 3 types of chips which have been obtained during the
demonstration; continuous chips, discontinuous chips and built-up-edge chips. From the
demonstration also, it was found that with the present of coolant, the chips produced
were softer compared with the process without coolant. The color of the chips been
produced were also different. Without coolant, the chips tend to become yellowish and
heat treated compared to the cutting process with coolant where the chips still
maintained it original color.

From the understanding which has been obtained during the demonstration, it can be
concluded that by knowing the chips formation we can determine the parameters shall
be used for machining selected materials.

References:
 1. Prof Madya Hj. Mohd Yusoff B Mohd Al-Rangi, Manufacturing Technology (Plant
α&β), 2005.
2. Serope Kalpakjian and Steven K. Schmid, Manufacturing Technology and
Technology (4th Edition), 2000
3. http://machine-tools.netfirms.com/01_Chip_Formation.htm

4. http://www.manufacturingcenter.com/tooling/archives/0305/0305tooling_around.a
sp

5. http://www.americanmachinist.com/304/Technologies/CuttingToolsAcc/Article/Fal
se/9131/

Members Contribution:

Bil Members Name Contribution

.
1. MOHAMMAD AMIR ILHAM BIN BAKRI Introduction and abstract
2. MUHAMMAD ARIF BIN NORDIN Procedure and apparatus
3. MARNI BT. IBRAHIM Results and conclusion
4. HAZRIL RIZMAN B. ROZELI Discussion and edit.