Advanced Manufacturing Processes

Subject Code: PI-4104

PPT-1

By
Dr. Tushar Banerjee
Assistant Professor
Production & Industrial Engineering
NIT Jamshedpur
Mechanism of Chip Formation

(ductile, brittle)

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Mechanism of Chip Formation in Ductile Materials

Fig. 1. Compression of work material ahead of tool tip (Ref: LM-05)

Mechanism of chip formation in ductile material is yielding and shearing

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 Mechanism of Chip Formation in Ductile Materials

Fig. 2. Piispanen’s Model of card analogy to explain chip formation in machining ductile materials
(Ref: LM-05) The pattern and extent of total
deformation of the chips due to
primary deformation of the chip ahead
of the tool face and secondary shear
deformations of the chip along the tool
face as shown in Fig. 3, depend on the
following factors.
• Work material
• Tool (material and geometry)
• Cutting velocity (Vc) and feed (So)
Fig. 3. Primary and secondary deformation zones
• Cutting fluid application 4
in the chip (Ref: LM-05)
Mechanism of Chip Formation in Brittle Materials

Fig. 4. Development and propagation of crack causing chip separation in brittle material
(Ref: LM-05)

Mechanism of chip formation in brittle material is fracture

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Mechanism of Chip Formation in Brittle Materials

Fig. 5. Schematic view of chip formation in machining brittle materials (Ref: LM-05)

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Geometry and Characteristics of Continuous Chip Formation

Fig. 6. Geometrical features of continuous chip formation (Ref: LM-05)

Fig. 6

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Geometry and Characteristics of Continuous Chip Formation
…………………… (1)

…………………… (2)

…………………… (3)

…………………… (4)

eq. (4)

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Geometry and Characteristics of Continuous Chip Formation

Fig. 7

Fig. 7. Role of rake angle and chip-tool interface friction on chip-reduction coefficient
(Ref: LM-05)

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 Shear Plane and Shear Zone Theories
It is considered that chip is formed abruptly along a shear plane only. But practically it is
not feasible, because, then change in velocity from cutting velocity (Vc) to chip flow
velocity on rake surface (Vf) and plastic strain from almost nil to high value would have
been in no time resulting in infinite retardation and strain rate. Practically, the shear
deformation occurs over a zone (instead of across a plane) as indicated in Fig. 14.
However, the thickness of the shear zone comes to be very low, about 20 μm at high
speed machining. Due to this shear plane theory is conveniently used for general study.

Fig. 8. (a) Shear plane and (b) shear zone theories

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 Shear Angle

Fig. 9. Shear plane and shear angle in chip formation (Ref: LM-05)

8 11
 Shear Angle

(8)

…………………… (5)

…………………… (6)

(6)

…………………… (7)
(6)
(6) (4)

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 Cutting Strain

Fig. 10. Cutting strain (Ref: LM-05)

…………………… (8) 13
 References
Text Books:
1. ‘Machining & Machine Tools’ by A. B. Chattopadhyay, Wiley India
2. ‘Metal Cutting-Theory & Practice’ by Amitabha Bhattacharyya, New Central
Book Agency

Reference Books:
1. ‘Metal Cutting Principles’ by Milton C. Shaw, Oxford University Press
2. ‘Manufacturing Science’ by A. Ghosh & A. K. Mallick, East-West Press Pvt. Ltd.
Online Resources:
1. https://nptel.ac.in/courses/112/105/112105127/
2. https://nptel.ac.in/courses/112/105/112105126/

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