Chip-Type Machining Processes

Chip-Type Machining Processes
General Manufacturing Processes Engr.-20.2710

Instructor - Sam Chiappone
Basic Mechanics of Metal
Cutting
 Metal ahead of the cutting tool is compressed. This
results in the deformation or elongation of the
crystal structure—resulting in a shearing of the
metal. As the process continues, the metal above the
cutting edge is forced along the “chip-tool”
interference zone and is moved away form the work.
GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
Basic Mechanics of Metal
Cutting
GMP-20.271
Institute
Chip Formations
 During this process (3) basic types of chips are

formed:
– Discontinuous
– Continuous
– Continuous with a built-up edge (BUE)
GMP-20.271
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Discontinuous
 Typically associated with brittle metals like –Cast
Iron
 As tool contacts work, some compression takes
place
 As the chip starts up the chip-tool interference
zone, increased stress occurs until the metal
reaches a saturation point and fractures off the
workpiece.
GMP-20.271
Institute
Discontinuous
 Conditions which favor this
type of chip
– Brittle work material
– Small rake angles on cutting
tools
– Coarse machining feeds
– Low cutting speeds
– Major disadvantage—could
result in poor surface finish
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Institute
Continuous
 Continuous “ribbon” of metal that flows up the
chip/tool zone.
 Usually considered the ideal condition for
efficient cutting action.
GMP-20.271
Institute
Continuous
 Conditions which favor this type of chip:
– Ductile work
– Fine feeds
– Sharp cutting tools
– Larger rake angles
– High cutting speeds
– Proper coolants
GMP-20.271
Institute
Continuous with a built-up
edge(BUE)
 Same process as continuous, but as the metal
begins to flow up the chip-tool zone, small
particles of the metal begin to adhere or weld
themselves to the edge of the cutting tool. As the
particles continue to weld to the tool it effects the
cutting action of the tool.
GMP-20.271
Institute
Continuous with a built-up
edge(BUE)
 This type of chip is common in
softer non-ferrous metals and
low carbon steels.
 Problems
– Welded edges break off and can
become embedded in workpiece
– Decreases tool life
– Can result in poor surface
finishes
GMP-20.271
Institute
Heat and temperature in
machining
 In metal cutting the power input into the process
in largely converted to heat.
 This elevates the temperature of the chips,
workpiece, and tool.
 These elements along with the coolant act as heat
sinks.
GMP-20.271
Institute
Coolants/Cutting fluids
 Cutting fluids are used extensively in metal
removal processes.
– Act as a coolant, lubricant, and assist in removal of
chips.
– Primary mission of cutting fluids is to extend tool life
by keeping keep temperatures down.
– Most effective coolant is water….BUT is hardly ever
used by itself. Typically mixed with a water soluble oil
to add corrosion resistance and add lubrication
capabilities.
GMP-20.271
Institute
Issues Associated With Coolants
 Environmental
 Machine systems and maintenance
 Operators safety
GMP-20.271
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Machining Operations
 Machining operations can be classified into two
major categories:
– Single point = turning on a lathe
– Multiple tooth cutters = pocket milling on a vertical
milling machine
GMP-20.271
Institute
Tool Selection Factors
 Inputs
 Work material
 Type of cut
 Part geometry and size
 lot size
 Machinability data
 Quality needed
 Past experience of the decision maker
GMP-20.271
Institute
Constraints
 Manufacturing practice
 Machine condition
 Finish part requirements
 Workholding devices
 Required process time
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Outputs
 Selected tools
 Cutting parameters
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Institute
Tool Selection Process
GMP-20.271
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Elements of an Effective Tool
 High hardness
 Resistance to abrasion and wear
 Strength to resist bulk deformation
 Adequate thermal properties
 Consistent tool life
 Correct geometry
GMP-20.271
Institute
Tool Materials
 Wide variety of materials and compositions are
available to choose from when selecting a cutting
tool
GMP-20.271
Institute
Tool Materials
 They include:
– Tool steels - low end of scale. Used to make some
drills, taps, reamers, etc. Low cost equals low tool life.
– High speed steel(HSS) - can withstand cutting
temperatures up to 1100F. Have improved hardness
and wear resistance, used to manufacture drills,
reamers, single point tool bits, milling cutters, etc.
HSS cutting tools can be purchased with additional
coatings such as TiN which add additional protection
against wear.
GMP-20.271
Institute
Tool Materials
– Cobalt - one step above HSS, cutting speeds are
generally 25% higher.
– Carbides - Most widely used cutting tool today.
Cutting speeds are three to five times faster than HSS.
Basic composition is tungsten carbide with a cobalt
binder. Today a wide variety of chemical compositions
are available to meet different applications. In addition
to tool composition, coatings are added to tool
materials to incerase resistance to wear.
GMP-20.271
Institute
Tool Materials
– Ceramics - Contain pure aluminum oxide and can cut at
two to three times faster than carbides. Ceramic tools
have poor thermal and shock resistance and are not
recommended for interrupted cuts. Caution should be
taken when selecting these tools for cutting aluminum,
titanium, or other materials that may react with
aluminum oxide.
GMP-20.271
Institute
Tool Materials
– Cubic Boron Nitride(CBN) - This tool material maintains its
hardness and resistance to wear at elevated temperatures and
has a low chemical reactivity to the chip/tool interface.
Typically used to machine hard aerospace materials. Cutting
speeds and metal removal rates are up to five times faster than
carbide.
– Industrial Diamonds - diamonds are used to produce smooth
surface finishes such as mirrored surfaces. Can also be used in
“hard turning” operations to eliminate finish grinding
processes. Diamond machining is performed at high speeds
and generally fine feeds. Is used to machine a variety of
metals.
GMP-20.271
Institute
Tool Geometry
 The geometry of a cutting tool is determined by
(3) factors:
– Properties of the tool material
– Properties of the workpiece
– Type of cut
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Institute
Tool Geometry
 The most important geometry’s to consider on a
cutting tool are
– Back Rake Angles
– End Relief Angles
– Side Relief Angles
GMP-20.271
Institute
Tool Geometry
GMP-20.271
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Rake Angles
 Back-Allows the tool to shear the work and form
the chip. It can be positive or negative
– Positive = reduced cutting forces, limited deflection of
work, tool holder, and machine
– Negative = typically used to machine harder metals-
heavy cuts
 The side and back rake angle combine to from the
“true rake angle”
GMP-20.271
Institute
Rake Angles
 Small to medium rake angles cause:
– high compression
– high tool forces
– high friction
– result = Thick—highly deformed—hot chips
GMP-20.271
Institute
Rake Angles
 Larger positive rake
angles
– Reduce compression and
less chance of a
discontinuous chip
– Reduce forces
– Reduce friction
– Result = A thinner, less
deformed, and cooler chip.
GMP-20.271
Institute
Rake Angles
 Problems….as we increase the angle:
– Reduce strength of tool
– Reduce the capacity of the tool to conduct heat away
from the cutting edge.
– To increase the strength of the tool and allow it to
conduct heat better, in some tools, zero to negative rake
angles are used.
GMP-20.271
Institute
Negative Rake Tools
 Typical tool materials which utilize negative rakes
are:
» Carbide
» Diamonds
» Ceramics
 These materials tend to be much more brittle than
HSS but they hold superior hardness at high
temperatures. The negative rake angles transfer the
cutting forces to the tool which help to provide added
support to the cutting edge.
GMP-20.271
Institute
Negative Rake Tools
GMP-20.271
Institute
Summary Positive vs. Negative
Rake Angles
 Positive rake angles
– Reduced cutting forces
– Smaller deflection of work, tool holder, and machine
– Considered by some to be the most efficient way to cut
metal
– Creates large shear angle, reduced friction and heat
– Allows chip to move freely up the chip-tool zone
– Generally used for continuous cuts on ductile materials
which are not to hard or brittle
GMP-20.271
Institute
Summary Positive vs. Negative
Rake Angles
 Negative rake angles
– Initial shock of work to tool is on the face of the tool
and not on the point or edge. This prolongs the life of
the tool.
– Higher cutting speeds/feeds can be employed
GMP-20.271
Institute
Tool Angle Application
 Factors to consider for tool angles
– The hardness of the metal
– Type of cutting operation
– Material and shape of the cutting tool
– The strength of the cutting edge
GMP-20.271
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Carbide Inset Selection
GMP-20.271
Institute
M1-Fine
M2-Medium
M3-S.S
M4-Cast iron
M5-General
Purpose
A.N.S.I. Insert Identification

System
ANSI - B212.4-1986 GMP-20.271
Institute
GMP-20.271
Institute

Chip-Type Machining Processes

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Chip-Type Machining Processes

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Chip-Type Machining Processes

General Manufacturing Processes Engr.-20.2710

 During this process (3) basic types of chips are

A.N.S.I. Insert Identification

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