Faculty of Engineering

Mechanical Engineering Dept. 3rd Year production engineering.

Benha M1371 theory of metal cutting
University Instructor: Dr. Ashraf Hassan Laboratory
experiments.

Experiment No (1)

Study of chip formation

1. Introduction:
In the machining process, layers of metal are removed from a workpiece by the action
of a wedge-shaped cutting tool. The piece of metal removed is called a chip, and in
practice it is possible to produce three distinct types of chip: a continuous chip, a
continuous chip with a built-up edge, and a discontinuous chip. The type of chip
produce in a particular machining operation depends on the work and tool material,
the geometry and speed of cutting process, and the existence or absence of
lubrication. The purpose of the experiment is to illustrate the various types of chip that
can be produced during machining and to examine the effect of lubrication on chip
formation.

2. Equipment:
a. Engine lathe or shaper.
b. Workpiece materials in tube form (for lathe) or plate form (for shaper) to
include:
i. Copper.
ii. A brass containing 70 percent copper and 30 percent zinc.
iii. Pure iron or mild steel.
c. Two high-speed steel cutting tools, one with a normal rake of 15 degree
and the other with a normal rake of 35 degree
d. A small quantity of carbon tetrachloride

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 e. Equipment for mounting, preparation, and metallographic examination of
the chip specimens.
3. Procedure:
The lathe, or shaper, is set up so that the workpiece material can be machined
orthogonally with high-speed steel cutting tool. The work piece and the cutting tool
should be carefully clean, and the cutting speed and feed set according to the material
being machined.
Once the full feed engagement has been applied, the cutting action is suddenly
stopped by disengaging the clutch. The specimen is the cut from the workpiece,
care being taken not to damage the chip in the region of the cutting zone. In the
lubricated test, carbon tetrachloride is applied to the tool and workpiece during
machining. Care must be taken in the use of the lubricant since toxic vapors are
produced by this chemical.
Each specimen is mounted, ground to reveal a section near the center, polished,
etched with the appropriate solution, and examined under a low-power
metallurgical microscope.
It should be noted that a specimen suitable for examination cannot be produced if
the chip is completely discontinuous. For this specimen it is necessary to choose
cutting conditions resulting in a chip that is continuous but exhibits discontinuous at
its side surfaces. When this specimen is prepared for metallographic examination,
a section is taken near aside surface.

2Page Dr. Ashraf Hassan theory of metal cutting Oct. 2021