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Chip Friction

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Motion of
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Chip formation

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2.2.2 Continuous Chip with Built-up Edge


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Built-up edge

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Fig. 2.5 

2.2.3 Discontinuous Chip


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 Fundamentals of Machining and Machine Tools

Normal and shear stresses


Normal stress

Tangential (shear)
stress

Distance along rake face

 
 

C
n
max

E
D K = n

K
A B
Sticking F
zone Slipping zone
l1 l2
ln

Tool

  
 

 
The distribution function of normal stress
 = 
where,  = constant
 = constant
 = distance from end of chip-tool contact.
If  is the normal stress on the rake face at a distance  from the end of
contact length.

 = max
   

 


where, max = max. normal stress at the cutting edge


 = natural contact length between tool and chip.
  





     
  
 

     

             


 
      

 



 


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Chip-tool Chip Face


interface
Flank
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Cylindrical Work-tool interface


tool edge

   
 55

2.9 CHIP VELOCITY


   
  
  
    
 
  
    
             
 
  

 



 

 


 

    


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Chip C
Vc Vs

tc Tool
C (90° +  – )
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t  
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A 90° –  
Workpiece B A
Velocity diagram V

Fig. 2.16 


  
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2.10 MACHINING WITH VARIABLE UNCUT CHIP THICKNESS


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(a) Positive slope (b) Negative slope

 


 
   
   

              
     
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(90° – e + e) C
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B A Workpiece
Velocity diagram V


  

 
 
  
  
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2.11.5 Shear Plane Angle


  
  





 



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2.12 MECHANICS OF TURNING PROCESS


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Tool feed 
Q
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f R. H. Turning
S 
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Fig. 2.20 


  

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Cutter Cutter

Workpiece Workpiece

Table feed Table feed

(a) Up-milling (b) Down-milling


 

 


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Rc – d 

A B D E

90° –  d

ft


   


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