CHIP FORMATION

Types of chips &Mechanism of chip formation

TYPES OF CHIPS
The shape and geometry of the chips
produced during cutting process throw
considerable light on type and quality of
that process
The chips produced fall into one of the
following types:
1.Discontinous Chips
2.Continous chip without built up edge
3.Continous chip with built up edge
4. Nonhomogenous chip

Discontinuous Chip
It consists of independent plastically
deformed segments which fall off as
separate, unconnected pieces or in some
cases may loosely adhere to each other
Dicontinous chips are formed in case of
brittle work material , cutting ductile work
material at very low speed large depth of
cut and small rake angles.
For ductile material such chips are not
desirable.

Continuous chips without

built up edge
Continous chips without built-up edge are
formed when the material ahead of the cutting
edge continuously deforms without fracture
followed by smooth flow of the chip up the tool
face
This type of chips are formed in case of cutting
ductile material at normal cutting speed, small
depth of cut, large rake angle and low friction on
tool face
This type of chip is most desirable.They are
associated with lower tool forces,better tool life
and good surface finish.

Continuous chips with built

up edge
The built up edge is mass of metal which
stinks on to the face of tool while the chip
shears past it.
The built up edge is formed by welding of
a section of chip material to the because
of high pressure and temperature.
Chips with built up edge are undesirable
because they result in higher power
consumption, lower tool life and poor
surface finish.

Non-homogenous Chips
Chips of this type are produced while
machining some steel and titanium alloys
at medium cutting speed.
They are characterised by formation of
notches on the side of chip away from
the tool while the side adjacent to tool is
smooth.
This type of chip is caused by non
uniform strain in material during chip
formation.

Mechanism of Chip
Formation
When a force is applied to the cutting
tool the material ahead of cutting edge is
deformed by process of shear.
Line AB in fig represents the dividing line
between the work and the chip.Line AB
describes projection of shear plane.
Angle which shear plane makes with
the direction of tool travel is known as
shear angle.

 If thickness tc and length lc of a chip are

measured and compared with the
corresponding uncut dimension t and l,it
is found that tc>t and lc<l.
The ratio of t/tc is is known as chip
thickness ratio rc.
In metal cutting there are two major
shear zones primary zone and secondary
zone.
Primary shear zone is near the shear
plane while the secondary shear zone is
near the tool work piece interface.

Thank
You