CHIPS

In metal cutting, the cutting tool removes layer from the work piece to obtain a desired
shape and dimensions of the work piece. The layer separated (deformed layer) near the
cutting edge of the tool is known as chip.

TYPES OF CHIPS
Chip type mainly depend on the properties of work material and the conditions of cutting,
i.e. Cutting speed, depth of cut, Rake angle, feed, use of cutting fluid etc.
i) Discontinuous or segmental chip
ii) Continuous or ribbon type chip
iii) Continuous chip with built up edge
iv) Non-homogenous chip

1. SEGMENTAL (DISCONTINOUS) CHIP

Segmental chips are produced by the actual fracture into small pieces a head of the cutting
edge. The fracture or rupture of the work piece material takes place during plastic
deformation. These chips are produced while machining brittle materials like cast iron or

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while cutting ductile material like mild steel at very low speed, greater depth of cut and
small rake angle.
Discontinuous chips are not desirable due to the poor surface finish and excessive tool
wear.
2. CONTINOUS CHIP
These chips are produced when the material a head of the cutting edge continuously
deforms with fracture or rapture and flows off the tool face by plastic deformation in the
form of a ribbon (shows no sign of tear or discontinuities). Favorable factors of these types
are;
 Most ductile material (mild steel, copper)
 Low friction between the chip and tool face
 Normal cutting speed.
 Fine feed.
 Large rake angle
 Sharp cutting edge
 Optimum temperature at interface
 Efficient lubrication etc.
Chip breakers are essential for convenient chip handling and disposal.
3. CONTINOUS CHIP WITH BUILT-UP EDGE
Continuous chips with addition of building up of ridge of metal are formed on the nose of
the tool owing to the high friction generated between the chip and the tool face. This high
heat is resulting from a pile of compressed and highly stressed metal (in the form of
welding) forms at the tool nose or cutting tip and this creates a false cutting edge which
breaks a portion of chip into fragments or deposited on the work piece material and the
rest are carried away by the chip. Continuous chip with built-up edge will occur at the
following conditions;
 While machining ductile material at low cutting speed,
 High feed
 Low rake angle
 Without the use of cutting fluid etc.
This type is not desirable owing to high power consumptions, poor surface finish and
higher tool wear.
4. NON HOMOGENOUS CHIP
These chips are produced due to non-uniform strain in work piece material during the chip
formation. Temperature rise on the shear plane during shear deformation causes notches
on the free side of the chip, while the side adjoining the tool face is smooth. Non-
@ ATIR by Embati Philliam –Machining and Fitting Department. For info. 0781613252 or embatiph@gmail.com
homogenous chips are produced while machining typical material in which the yield
strength decreases with rise in temperature like steel, titanium alloy, etc., at medium
cutting speeds.

CHIP BREAKERS
While turning ductile material producing long unbroken continuous chip will be extremely
difficult to handle or to remove from the swarf tray requires breaking for comparatively
small pieces for easy handling or to minimize the working hazard. The device used to break
the long ribbon is known as chip breaker

It is either a groove ground along the cutting edge or a small step on the top face of the tool.
During turning the hardened chip flows on the tool face, strikes the leading edge of the tool
causes the chip to break into small pieces. Chip breakers are of groove, step and clamp
types.

@ ATIR by Embati Philliam –Machining and Fitting Department. For info. 0781613252 or embatiph@gmail.com