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Design of Adjustable Chip Breaker for PCD Turning Tools

Maochao Wu , Aibing Yu , Qiujie Chen , Yanlin Wang ,

Jiandong Yuan , Lei Sun , Jianying Chi

PII: S0020-7403(19)33272-2
DOI: https://doi.org/10.1016/j.ijmecsci.2019.105411
Reference: MS 105411

To appear in: International Journal of Mechanical Sciences

Received date: 29 August 2019

Revised date: 3 December 2019
Accepted date: 25 December 2019

Please cite this article as: Maochao Wu , Aibing Yu , Qiujie Chen , Yanlin Wang , Jiandong Yuan ,
Lei Sun , Jianying Chi , Design of Adjustable Chip Breaker for PCD Turning Tools, International Jour-
nal of Mechanical Sciences (2019), doi: https://doi.org/10.1016/j.ijmecsci.2019.105411

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Highlights
 An adjustable chip breaker is designed for PCD turning tools.
 Influence mechanisms of inclination angle and the position parameter of chip breaker on chip curling are
obtained.
 A simple set of equations are derived for designing chip breaker parameters, including inclination angle,
position parameter and height.
 A design method for chip breaker parameters of PCD tool is proposed.
 Design of Adjustable Chip Breaker for PCD Turning Tools

Maochao Wu, Aibing Yu*, Qiujie Chen, Yanlin Wang, Jiandong Yuan, Lei Sun, Jianying Chi

(Faculty of Mechanical Engineering and Mechanics，Ningbo University，Ningbo 315211, China)

Abstract: To obtain better chip breaking effect for most cutting parameters, a chip breaker which position on rake

face of tool can be adjusted is designed and analyzed. According to the structure and installation features of the

PCD insert, structure of adjustable chip breaker is designed. Through finite element simulation and cutting

experiments, the influences of chip breaker parameters on the radius of chip curl curvature were analyzed to

determine the parameters of chip breaker. Forces on chips and the chip breaking processes of PCD tool with chip

breaker were analyzed. The geometric relationships between chip breaker and chip were established. According to

the geometric relationship and the chip breaking criterion, the formulas of three chip breaker parameters were

deduced. A design method for chip breaker parameters of PCD tool was proposed. The research results show that

the radius of chip curl curvature decreases as the inclination angle increases and decreases as the position

parameter decreases. There is a threshold for both inclination angle and the position parameter of the chip breaker,

and if the threshold is exceeded, severe noise and chip build-up will occur. If the contact point between the chip

and the chip breaker is located in the selected segment of chip, the extrusion force between the chip and the chip

breaker will increase as the chip grows, which can cause the chip to crack and break easily. The influence

mechanisms of inclination angle and the position parameter of chip breaker on chip curling are obtained. A simple

set of equations are derived for designing chip breaker parameters, including inclination angle, position parameter

and height. A design method for chip breaker parameters of PCD tool is presented. The application of the chip

breaker can expand the chip breaking range of cutting parameters for PCD tools.

Key words: PCD; tool; chip; chip breaking; turning

Symbols
θ inclination angle of chip breaker Fx resultant force in the x direction
W position parameter of chip breaker Fy resultant force in the y direction
H height of chip breaker Mn clockwise moment
Rc radius of chip curl curvature Mr counterclockwise moment
γo rake angle εf chip breaking strain
αo orthogonal clearance angle εwnb clockwise bending strain of chip
κr major cutting edge angle εwp counterclockwise bending strain of chip
f feed rate εwb bending strain of chip
ap depth of cut ach chip thickness
k correction factor ac thickness of cut
vc cutting speed r outer radius of chip curl curvature
Lf tool-chip contact length ̂
𝐸𝑄 arc length of chip from point E to point Q
Fr the force that chip breaker acts on chips Ras ̂ to ach
ratio of 𝐸𝑄
Fn the force that workpiece acts on chips hef chip breaker effective height
β an evaluation index of chip curling degree ξ chip compression ratio
r1 radius of chip curl curvature after the chip r2 radius of chip curl curvature when the chip is
flows out through the chip breaker reversely broken

1 Introduction
PCD cutting tools have been widely used in high-speed precision machining of aluminum alloys [1, 2],
titanium alloys [3, 4] and non-ferrous matrix composites [5] in the automotive, aerospace, defense, and 3C
industries. However, there is one problem that the chips are difficult to be broken during the processes of cutting
aluminum alloy and titanium alloy materials for PCD tools [6]. If the chips cannot be broken, the continuous chips
will tend to tangle with workpiece or cutting tool in machining processes. This chip winding phenomenon may
cause some serious problems such as reducing the surface accuracy of the workpiece [7], shortening the tool life and
endangering the safety of workers. Usually, machine needs to be stopped periodically to remove the tangled chips,
but frequent downtime will affect the automation process and production efficiency [8]. Nowadays, chip breaking
has become one of the key factors affecting the automation production [9, 10]. If the chips can be broken into
appropriate lengths using effective chip breaking technology, the production efficiency can be improved, the
production cost can be reduced and the process of automated production can be promoted while ensuring the quality
of the workpiece.
At present, the main means of chip breaking are to fabricate chip breaking groove or raised chip breaker on the
rake face of the turning tool. Chip breaking groove is commonly used to break the chips for the cemented carbide
and high speed steel tools [11]. However, for PCD tools, it is difficult to machine chip breaking groove on the tool
rake face from the aspects of material forming and machining processes. For example, Silva et al points out that
there is no PCD chip breaking groove forming process at present [12], and Elkaserer et al shows that it is impossible
to determine the geometry of the chip breaking groove prior to the brazing stage during the production process of
brazed PCD inserts [13]. From the viewpoint of machining, laser processing and EDM are usually used to process
the chip breaking groove on the rake face of PCD tools after brazing. However, it is difficult to machine specific
geometries on the tool surface due to the characteristics of PCD material [14]. For example, if laser processing is
used to machine the chip breaking groove, the PCD tool is prone to be heated to generate defects such as
graphitization, cracks and pores, due to the poor heat resistance of the PCD material [15-17]. And these thermal
damages will reduce the performance of PCD tools. If the chip breaking groove is machined by EDM, the electrode
will be damaged and the surface roughness of the workpiece will be poor, due to the poor conductivity of the PCD
material [18]. In short, the problems of low processing efficiency, high cost and surface processing damage limit the
wide engineering application of PCD cutting tools with chip breaking groove in a certain extent.
In addition, the strength of the PCD insert and cutting edge will be reduced after the PCD tool rake face is
grooved due to the poor toughness of the PCD material. So, the PCD tool is prone to loss the use value. If the chip
breaker is used for chip breaking, the cutting edge can be protected to a large extent. In this paper, an adjustable chip
breaker is designed, which can achieve good chip breaking effect under various cutting parameters. The influence of
the chip breaker parameters on the radius of chip curl curvature Rc is analyzed by the finite element simulation
method. The range of the chip breaker parameters is determined through the calculation of geometrical relationships
and cutting experiments.

2 Structural design of adjustable chip breaker

Fig.1 shows the schematic diagram of unassembled chip breaker parts and PCD turning tool structure. The
adjustable chip breaker parts include fixed screw nut device, chip breaker and a few assembly gaskets, as shown
in Fig. 1(a). According to the PCD tool structure, as shown in Fig. 1(b), the chip breaker can be assembled on the
tool as an attachment, which is fixed by the fixed screw nut device, the assembly gaskets and the clamp, as shown
in Fig. 2. The clamp is pressed into the chip breaker dimple, which is filled with the assembly gasket to ensure the
reliable connection between the chip breaker and the clamp. In order to prevent the chip breaker from rotating, the
fixed screw is used to fix the chip breaker. When it is necessary to adjust the position of the chip breaker, first,
loosening the clamp and fixed nut, then moving the chip breaker to change the position parameter W shown in Fig.
2(a) and finally fixing the chip breaker again. In order to meet the various position parameter W, the specifications
of assembly gaskets are divided into three types, including 0.1 mm, 0.2 mm and 0.5 mm. There are some
advantages for this chip breaker structure. For example, the chip breaker can achieve good chip breaking
performance under most cutting parameters. The chip breaker can be used as an attachment of PCD turning tools.
The structure of chip breaker is designed according to the existed structure of the PCD turning tools, and the chip
breaker can be assembled to most commercial PCD turning tools. In addition, the chip breaker is simple in
structure, low in cost and easy to fabricate.

(a) Chip breaker parts (b) PCD turning tool

Fig. 1 Schematic diagram of chip breaker parts and PCD tool structure
 （a）Assembled structure （b）Assembled photo

Fig. 2 PCD tool with chip breaker

Significant findings on chip flow have been done by Stabler [19], Russell [20] and Young [21]. Using a
cutting edge chord method, Colwell [22] showed the chip flows approximately perpendicular to this chord
representing the major axis of the projected area of cutting. The model of Okushima and Minato [23] showed chip
flow is summation of elemental flow angles over the entire length of the cutting edge. On this basis, Hu et al
shows that the equivalent cutting edge is equivalent to the part of the cutting tool actually involved in the cutting
processes, and the chip flow direction is perpendicular to the equivalent cutting edge [24]. According to related
research jobs, the position of equivalent cutting edge can be determined [25, 26]. As shown in Fig. 3(a), if the chip
breaker is parallel to the equivalent cutting edge, the chip will flow vertically to the chip breaker. Fig. 3(a) is the
tool reference plane through point A. In the Fig. 3(a), point O is the center of nose radius of PCD insert tool, point
A is the intersection of the cutting edge and the straight line passing through point O and perpendicular to the
equivalent cutting edge. The chip breaker can promote the upward curling of the chip and cause the chip to flow to
the surface of workpiece. When the radius of chip curl curvature Rc is small enough, the chip can be broken, or
when the chip hits the workpiece, the strain of chip will increase instantaneously and cause the breaking of chips,
as shown in Fig. 3(b). The structure parameters of chip breaker, such as inclination angle θ, height H and position
parameter W, can affect the radius of chip curl curvature Rc. So, the range of these three parameters needs to be
determined in this study.

(a) Cutting reference plane (b) G-G

Fig. 3 Schematic diagram of chip breaking processes

Some researchers have studied the structure of the chip breaking groove, such as Fang [27], Worthington and
Redford [28] and Kaldor [29]. According to the function of the chip breaking groove, the structure of chip
breaking groove can be divided into two parts, part A and part B, as shown in Fig. 4. The function of part A is
equivalent to increasing the rake angle of turning tool, and the chip will be led into the chip breaking groove to
promote chip curling. However, the part A of chip breaking groove may reduce the strength of PCD cutting edge.
The part B can further promote chip curling to reduce the radius of chip curl curvature. It is part B that causes the
chip to break. If a chip breaker is used to break chips, this is equivalent to using the function of part B of chip
breaking groove, and the disadvantage of reducing the strength of the cutting edge in part A can be avoided. The
chip breaker can protect PCD insert tool from chipping of cutting edge. In Fig.4, we select the commonly used
dimensional parameters of part B of chip breaking groove of commercially available cemented carbide as the
initial design reference of chip breaker parameters of PCD insert tool. Moreover, the finite element simulation
technology is used to adjust the parameters of chip breaker to achieve good chip breaking effect of PCD insert
tool.

Fig. 4 Design reference of chip breaker parameters

3 Experimental materials and methods

3.1 Experimental materials

7075-T651 aluminum alloy bars were selected as workpiece material. 7075-T651 aluminum alloy have
characteristics of good plasticity, toughness and adhesion after heat treatment and pre-stretching, for example,
tensile strength of 524 MPa, yield strength of 455 MPa and the elastic modulus of 71.7 GPa. Chemical composition
of 7075–T651 is given in Table 1. Kamiya and Yakou carried out the cutting experiments of various types
aluminum alloy, and found that chips of 7075-T651 aluminum alloy were difficult to break and cutting speed has
little influence on chip breaking effect [30]. The commercially available PCD insert tools were chosen as turning
tool material. The geometric parameters of PCD turning tools were as follows: rake angle γo=0°, orthogonal
clearance angle αo=10°, major cutting edge angle κr=110°. The recommended cutting parameters of PCD insert
tools for aluminum alloy are as follows: the cutting speed was vc=800 m/min, the depth of cut ap=1 mm, and the feed
rate f=0.2 mm/r. The commercially available PCD tool with chip breaking groove machined by laser processing is
shown in Fig. 5. The high speed steel was selected as the material of chip breaker.
 Fig. 5 PCD tool with chip breaking groove
Table 1 Chemical composition of 7075–T651.

Chemical element Si Fe Cu Mg Mn Zn Ti Cr
wt. % 0.08 0.14 1.4 2.4 0.03 5.4 0.03 0.21

3.2 Experimental methods

According to the commercially available cemented carbide tool, parameters of part B of chip breaking groove
are Ws=1.8 mm, L=0.43, hn=1.2 mm and θ=40° in Fig.4. Through calculation and adjustment, the initial design
parameters of the chip breaker were W=0.83 mm and θ=40°. To ensure the chip can hit the chip breaker, we
increase the H value appropriately, let H = 5 mm. WEDM method was used to machine chip breakers with
parameters of height H= 5 mm and the inclination angle θ = 40°, 50°, 60°, 65°, 70° and 75° respectively. These
chip breakers were assembled on the rake face of six PCD tools respectively. During the turning experiments, the
position parameters W of the chip breaker were adjusted to 2.3 mm, 2.0 mm, 1.7 mm, 1.4 mm, 1.1 mm and 0.8
mm, respectively.
Cylindrical dry turning experiments were carried out on CAK3665 type CNC lathe. Cutting parameters were as
follows: the cutting speed vc=800 m/min, the depth of cut ap=0.5-2.5 mm, and the feed rate f=0.1-0.5 mm/r. The
chips were collected and chip shapes were observed with KH-8700 type stereomicroscope. In order to ensure that
the chip breaker is always parallel to the equivalent cutting edge during the adjustment of cutting parameters, the
depth of cut ap and the feed rate f need to be adjusted proportionally. According to recommended cutting parameters
of commercial PCD tools, the ratio of ap to f was set as 5.
The 2D FEM cutting simulation model of PCD tool was established. The modeling methodology based on
plane-strain rigid-plastic slip-line theory has been employed by many machining researchers, such as Oxley [31],
Lee [32] and Johnson [33], with various types of cutting models having been developed. On this basis, the cutting
model proposed by Fang considers the influence of the cutting edge radius on the curl of chip [34, 35]. Therefore,
the cutting simulation model of our study considers the influence of the cutting edge radius of PCD tool on chip
curling, as shown in Fig. 6. Significant findings on material model have been done by Oxley and Hastings [36],
Johnson and Cook [37] and Lee [38]. In this paper, the workpiece was modeled as an elasto–plastic material with
damage, whereas the tool was modeled as a rigid body. In metal cutting, the chip formation process involves large
plastic deformation at high temperature and strain rate, where the stress and temperature fields mutually influence
each other. Hence, the problem was solved by applying a fully coupled thermo–mechanical simulation algorithm.
The thermo-mechanical behaviour of the 7075-T651 alloy was modeled using the J–C constitutive equation. An
equation describing the flow stress with strain, strain rate and temperature is given by
𝑛 𝜀̇P 𝑇 − 𝑇0 𝑚
σ = [𝐴 + 𝐵(𝜀p ) ] [1 + 𝐶 ln ( )] [1 − ( ) ] (1)
𝜀̇0 𝑇m − 𝑇0
where σ denotes the equivalent flow stress, 𝜀p is the equivalent plastic strain, 𝜀̇P is the equivalent strain rate, 𝜀̇0
is the reference strain rate, T is the temperature of the work material, 𝑇m is the melting temperature and 𝑇0 is the
room temperature. The material constants can be interpreted as follows: A is the yield strength coefficient, B is the
hardening modulus, C is the strain rate sensitivity coefficient, n is the hardening coefficient, and m is the thermal
softening coefficient.
The FEM simulation of the chip formation is performed by implementing a damage model which can describe
the material behaviour when damage occurs. In the present study, the J–C failure model, which is based on the
equivalent plastic strain at failure 𝜀f , is used as a criterion for damage initiation. 𝜀f is defined as:
𝜀𝑝 𝜀̇P 𝑇 − 𝑇0
𝜀f = 0𝐷1 + 𝐷2 exp .𝐷3 /1 [1 + 𝐷4 ln ( )] [1 − 𝐷5 ( )] (2)
σ 𝜀̇0 𝑇m − 𝑇0
where 𝜀p denotes the pressure stress and σ is the von Mises stress, D1 to D5 are damage constants. The values of
physical properties and the J–C material constants for the 7075-T651 alloy are shown in Table 2. The physical
properties of the PCD tool are presented in Table 3. The influence of the chip breaker parameters on the radius of
chip curl curvature Rc was studied according to the simulation results, which can provide a reference for the
theoretical calculation of chip breaker parameters.

Fig. 6 Cutting simulation model

Table 2 J–C material constants for the 7075-T651 alloy [39, 40].
Property Value
Elastic modulus (GPa) 71.7
Poissons coefficient 0.33
Melting temperature (K) 908
Specific heat (J/(kg·K)) 0.786T+839.2
Thermal conductivity (W/(m·k)) -0.0002T2+0.1366T+128.63
Thermal expansion (μm/(m·K)) 25.2
Density (kg/m3) 2810
A (MPa) B (MPa) n C m 𝜀̇0 (s-1) T0 Tm
Plasticity parameters
527 575 0.72 0.017 1.61 1 25 635
D1 D2 D3 D4 D5
Failure parameters
0.110 0.572 -3.446 0.016 1.099
 Table 3 Physical properties of the PCD tool.
Property Value
Elastic modulus (GPa) 900
Poissons coefficient 0.1
Specific heat (J/(kg·K)) 471.5
Thermal conductivity (W/(m·k)) 700
Density (kg/m3) 3500

4 Results and discussion

4.1 Chip breaking effect

Fig. 7 shows chips produced by different PCD tools, where the unit of the reference ruler is mm. For common
PCD tool without chip breaking measures, the chip cannot be broken, and chips are winding disorderly, as shown in
Fig. 7(a). Fig. 7(b) shows chips produced by PCD tools with chip breaking groove. When the feed rate f is 0.1 mm/r,
most of chips are long spiral chips and a slight winding phenomenon is occurred during cutting operations. For
f=0.2 mm/r, there are more short spiral chips and a few C-shaped chips. But for f=0.3 mm/r or 0.4 mm/r, the chip
cannot be broken, and chips are severely entangled during turning processes. Therefore, there usually exists a chip
breaking range of cutting parameters for PCD tools with chip breaking groove. Fig. 7(c) shows the chip produced
by PCD tools with adjustable chip breaker. It can be seen that the chip can be broken under different feed rates and
most chips are C-shaped chips. Therefore, compared to chip breaking groove, the adjustable chip breaker can
expand chip breaking range of cutting parameters for PCD tools.

f=0.1 mm/r f=0.2 mm/r f=0.3 mm/r f=0.4 mm/r

(a) PCD tool without chip breaking measure

f=0.1 mm/r f=0.2 mm/r f=0.3 mm/r f=0.4 mm/r

(b) PCD tool with chip breaking groove

 f=0.1 mm/r f=0.2 mm/r f=0.3 mm/r f=0.4 mm/r

(c) PCD tool with chip breaker

Fig. 7 Chips produced by different PCD tools

4.2 Influence of chip breaker parameters on radius of chip curl curvature Rc

4.2.1 Inclination angle θ
Fig. 8(a) shows FEM simulated chips produced by PCD tools with chip breaker with different inclination
angle. The parameters of chip breaker are as follows: W=2 mm, H=5 mm and the inclination angle θ=40° - 75°. We
have the depth of cut ap=1 mm and the feed rate f=0.2 mm/r. In Fig. 8(b), the radius of chip curl curvature R c
decreases as the inclination angle θ increases. However, when θ increases to a certain value, θ=75°, the chips cannot
flow out. We carried out above 6 cutting experiments respectively. We found that the chip could not be broken and
wound around the workpiece surface. For example, for θ=65°, we can observe the unbroken and entangled chips in
Fig. 9(a). However, for θ=75°, harsh friction noise generated during cutting operations. The chip piled between chip
breaker and tool rake face, as shown in Fig. 9(b). In addition, the pile-up chips scratched machined surface of
workpiece. Rough machined surface was obtained as shown in Fig. 9(c). According to above simulation and
experimental results, we know that the inclination angle of chip breaker affect the radius of chip curl curvature Rc,
and the radius of chip curl curvature Rc decreases as the inclination angle θ increases, but the value of θ should be
smaller than a certain threshold.

(a) Chips produced by PCD tools with different inclination angle of chip breaker

(b) Relationship between radius of chip curl curvature and inclination angle of chip breaker
Fig. 8 Effect of inclination angle of chip breaker on the radius of chip curl curvature
 (a) Chip winding (b) Chip piled (c) Workpiece scratched surface
Fig. 9 Turning experimental results of PCD tool with different θ

4.2.2 Position parameter W

Fig. 10(a) shows the simulated cutting processes of PCD tools with chip breaker. The parameters of chip
breaker are as follows: θ=65°, H=5 mm and different positional parameters W from 0.8 mm to 2.3 mm. The depth of
cut is ap=1 mm and the feed rate is f=0.2 mm/r. From Fig. 10(b), the radius of chip curl curvature Rc decreases as the
position parameter W of chip breaker decreases. In Fig. 10(a), when W decreases to a certain value, W = 0.8 mm, the
chip pile between tool rake face and chip breaker. Our cutting experimental results show that unbroken chips
wound around the workpiece when we set positional parameter W≥2 mm. When 1.1 mm ≤W≤1.7 mm, the chip can
be broken, and chips are mostly C-shaped. For example, when W = 1.5 mm, the simulation result and experimental
result of chips are mostly C-shaped chips, as shown in Fig. 11. Fig. 12 shows the microscopic photographs of chips
obtained from cutting experiments. In Fig. 12, we can observe that the radius of chip curl curvature Rc decreases as
the position parameter of chip breaker W decreases. Similar to Figs. 9 (b) and (c), harsh friction noise generated
during cutting operation and chips piled between chip breaker and tool rake face when we set W = 0.8 mm. From
above simulation and experimental results, the position parameter of chip breaker W can affect the radius of chip
curl curvature Rc, and the radius of chip curl curvature Rc decreases as the position parameter of chip breaker W
decreases, but the value of position parameter W should be bigger than a certain threshold.

(a) Chips produced by PCD tools with different position parameter of chip breaker
 (b) Relationship between radius of chip curl curvature and position parameter of chip breaker
Fig. 10 Effect of position parameter of chip breaker on the radius of chip curl curvature

(a) Simulation chips (b) Experimental chips

Fig. 11 The result of experimental and simulation chips when W=1.5 mm

(a) W=1.1 mm (b) W=1.4 mm (c) W=1.7 mm

Fig. 12 The microscopic photographs of chips

The radius of chip curl curvature Rc is affected by both the inclination angle θ and the position parameter W
of the chip breaker. The radius of chip curl curvature Rc will be decreased as the inclination angle θ increases or
the positional parameter W decreases. But, there exists a threshold value for θ and W. When W and θ reach their
threshold value, the normal cutting process cannot be carried out. In order to explain this phenomenon, we analyze
the force of chip during cutting processes.
During the cutting process, the chip will slide along the tool rake surface. As shown in Fig. 13 (a), the chip
begins to curl as the chip slips to a certain distance which is the tool-chip contact length Lf. Balaji and Ghosh
proposed that the chip flow direction can be affected by restricting the tool-chip contact length [7]. What is more,
from the study of Stevenson [41] and Madhavan [42], we can know if the friction between the tool and chip is
reduced, the tool-chip contact length Lf will be increased, and the degree of curl of chip will be reduced. The same
conclusion was gotten that high friction on the tool rake face leads to an increase in chip curvature by Shi and
Ramalingam [43]. While PCD tool has a very low coefficient of friction, the tool-chip contact length and the
radius of chip curl curvature Rc will be increased without any chip breaker measures. In Fig. 13 (a), point A is the
starting point of chip curling, point B is the end of chip point. Both point A and point B are located on the center
line of the chip. In the absence of chip breaking measures, the chip will flow along the trajectory of B0. If a chip
breaker is applied, the chip will change its’ flow direction and flow along the trajectory of B 1. The chip breaker
will cause chips to curl further. In order to measure the degree of chip curling, an angle β between the straight line
AB and tool rake face is used as an evaluation index. According to the trajectory of B0, it can be seen that if the
position parameter W of chip breaker increases, the degree of chip curling when the chip hits the chip breaker also
increases. In other words, β increases as W increases.
As shown in Fig. 13(b), when the chip hits the chip breaker, the force on chip can be decomposed into two
components, force Fr perpendicular to chip breaker and friction force Ff. Taking the direction of straight line BA
as the x-axis, we establish a rectangular coordinate system. Fr and Ff are respectively decomposed along the x and
y directions. Let Fx be the resultant force in the x direction, let Fy be the resultant force in the y direction. From
Fig. 13(b), we have
𝐹x = 𝐹r1 + 𝐹f1 （3）
𝐹y = 𝐹r2 − 𝐹f2 （4）
Where,
𝐹r1 = 𝐹r sin(𝜃 − 𝛽) （5）

𝐹r2 = 𝐹r cos(𝜃 − 𝛽) （6）

𝐹f1 = 𝐹f cos(𝜃 − 𝛽) （7）

𝐹f2 = 𝐹f sin(𝜃 − 𝛽) （8）

So,
𝐹x = 𝐹r sin(𝜃 − 𝛽) + 𝐹f cos(𝜃 − 𝛽) （9）

𝐹y = 𝐹r cos(𝜃 − 𝛽) − 𝐹f sin(𝜃 − 𝛽) （10）

The function of Fy is to promote the chip curling. When W is fixed, β is also unchanged. According to Eq.
(10), if θ increases, Fy will become smaller or even tend to zero. In this case, the chip cannot be curled, so chips
will be piled between tool rake face and chip breaker, as shown in Fig. 9 (b). At this time, Fr and Ff will gradually
increase as the further increase of chips. According to Eq. (9), the force Fx will increase which may cause the
increasing of extrusion force and the friction force between the chip and the tool, and the tool-chip contact length
Lf will be further increased. So, the harsh friction noise was generated during cutting experiments of PCD tool
with chip breaker of inclination angle θ = 75° in Fig. 9(b). Therefore, there is a maximum value of θ when the
relationship between the radius of chip curl curvature Rc and the inclination angle of chip breaker θ is studied.
Similarly, if the θ is unchanged and the β is decreased, the same phenomenon will occur. So, there is a
minimum value of β. Due to the reason that β decreases as W decreases, there is a minimum value of W. The study
of Shi et al shows that the positional parameter W of the chip breaker needs to be larger than the tool-chip contact
length Lf, that is W>Lf [44]. While Lf is changed as the cutting parameters change. Therefore, in order to realize
the chip breaker effective chip breaking under various cutting parameters, it is necessary to adjust the chip breaker
position parameter W as the cutting parameter changes. So, the chip breaker that can adjust W was designed in this
study.
 (a) The trajectory of chip flowing (b) Forces on chip

Fig. 13 Force analysis of chip

4.3 Design of chip breaker parameters

4.3.1 Chip breaking process
Fig. 14 is the simulated chip breaking process of PCD tool with chip breaker. As shown in Fig. 14 (a) and (b),
the internal stress and strain of chip which contacts with the chip breaker is biggest, and increase as the growth of
chips. So, it is prone to generate cracks within chips in contact with chip breaker as shown in Fig. 14 (c). After the
chip is cracked, the strength of the chip is decreased. The chip has the lowest strength at the crack comparing with
other parts of the chip. So, the crack extends from the inside to the outside of curved chip shown in Fig. 14 (d).
Finally, two C-shaped chips are formed and connected by outer surface, as shown in Fig. 14 (e). Fig. 15 is a type
of the chip collected during cutting experiments. We can observe that two C-shaped chips are connected only by
outer surface. But there exists weak joint strength between two connected C-shaped chips. When subjected to a
small destructive force, the two connected C-shapes chips will be separated. Due to the vibration and swing
during the cutting processes, the connected C-shaped chips are usually separated. So, most of collected chips in
cutting experiments are C-shaped chips and a few chips are connected C-shaped chips, as shown in Fig. 7 (c) and
Fig. 11 (b).

(a) Internal stress (b) Internal strain (c) Crack generation (d) Motion track of chip

(e) C-shaped chips

 Fig. 14 Chip breaking process

Fig. 15 A chip collected in the experiment

Chip breaking is a process of crack extension. So, the key of the chip breaking is whether cracks can be
generated within chips. Then, what conditions can cause cracks in chips easily?
In Fig.16, the counterclockwise moment Mr is generated by the force Fr which the chip breaker acts on chips.
Mr can promote further curling of chips and cause the reduction of the radius of chip curl curvature after the chip
flows out through the chip breaker r1. So, the counterclockwise bending strain of chip εwp will be increased
according to the calculation formula of εwp, as shown in Eq. (11). When the chip hits the workpiece surface, an
upward force Fn is generated, which can produce a clockwise moment Mn on the chip. The radius of chip curl
curvature when the chip is reversely broken r2 will be increased due to Mn. So, the clockwise bending strain of
chip εwnb will be increased according to Eq. (12). But, before the chip hits the workpiece surface, there is no
clockwise bending strain of chip εwnb. When the chip hits the workpiece surface, εwnb is generated instantaneously.
As shown in Fig. 16, there is not only εwp but also εwnb in E region. So, the bending strain εwb in E region will be
increased instantaneously when the chip hits the workpiece surface. Due to the rapid increase of the stress and
strain in E region, the mesoscopic unevenness structure of material is prone to generate. When the chip hit the
workpiece surface, the force Fr is increased instantaneously, which is equivalent to apply an impact load to the E
region of chip. The related studies[45-47] show that the micro-cracks and micro-cavities will be generated when
the mesoscopic unevenness material is subjected to an impact load. The micro-cracks and micro-cavities will
cause the initiation and propagation of cracks. Therefore, the chip is prone to cracks if force Fr is large enough.

𝜀 p = (11)
1

1 1 (12)
𝜀 = ( − )
1 2

In addition, Nakayama proposed that the chip will be broken when the bending strain εwb reaches to the chip
breaking strain εf, εwb≥εf [48]. Equation can be expressed as
1 (13)
𝜀 = ( − ) 𝜀f
1 2
Where, αch is the chip thickness, r1 is the radius of chip curl curvature after the chip flows out through the
chip breaker, r2 is the radius of chip curl curvature when the chip is reversely broken, εf is the chip breaking strain,
εwb=εwp+εwnb.
From Eq. (13), the smaller the value of the radius of chip curl curvature r1 is, the bigger the chip bending
strain εwb is, and the more easily the chip breaks. The moment Mr can promote further curling of the chips to
reduce r1. So, if the moment Mr becomes bigger, chips will be easier to break. Since Fr is proportional to M r, the
bigger the Fr is, the more easily the chip breaks.
 Fig. 16 Forces and moments on chip
According to the above analysis, we can know that chip breaker exert a force Fr on chip during the cutting
processes. The force Fr can affect the cracking and breaking of chip. However, Fr is affected by the inclination
angle of chip breaker θ. In order to make the chip easy to break, it is necessary to design the range of inclination
angle θ to increase the force Fr.
4.3.2 Range of the inclination angle θ
Fig. 17 (a) is the simulation of chip flow trajectory. Firstly, the chip curls naturally. When the chip hits the
workpiece surface, the force Fn is generated. The Fn will change the movement direction of the chip and increase
the value of radius of chip curl curvature. Comparing the chip position at different time, we can find that the
change of the chip position mainly occurs in segment C, while little change in segment D of chip occurs, as shown
in Fig. 17 (b). Then, we can measure the values, θb1=30° and θb2=60°. Therefore, if the contact point between the
chip and the chip breaker is located in the selected segment C of chip, as shown in Fig. 17 (b), the extrusion force
Fr between the chip and the chip breaker will increase as the chip grows, which can cause the chip to crack and
break easily.

(a) Chip flow trajectory

 (b) Comparison of chip position at different times
Fig. 17 Chip flow process
In Fig. 18, point A is the center of the circle that the chip is located, r is the outer radius of chip curl curvature,
AY is the horizontal straight line and YG is perpendicular to AY. From the geometric relationship of quadrilateral
AEFG, we have
1 + ∠𝐴 𝐹 + ∠ 𝐹𝐸 + ∠𝐹𝐸𝐴 = (14)
where
∠ 𝐹𝐸 + 𝜃 = (15)

∠𝐴 𝐹 = ∠𝐴 𝐺 + (16)

∠𝐴 𝐺 = (17)

∠𝐹𝐸𝐴 = (18)

Substituting Eqs (15), (16), (17) and (18) into Eq. (14) , we have
𝜃= 1 + (19)
According to above analysis，the contact point E between chip and chip breaker shown in Fig.18 should be in
the selected segment C in Fig. 17(b). Where θb1 =30° and θb2 = 60°, then α1∈ (60°, 90°). Substituting α1 into Eq.
(19), we can get θ∈(60° + γo , 90° + γo). From the above analysis in seciton 4.2.1, we have θ < 75°, then θ∈( 60°
+ γo , 75°). If the value of parameter θ is within above range, there will be a higher extrusion force Fr, which can
cause chip to break and flow out smoothly. For example, when rake angle γo =0, according to Eq. (19), the
parameter θ value that satisfies the chip breaking condition should be θ∈(60°, 75°). In Figs. 11 (a) and (b), chips
can be broken effectively by the PCD tool with chip breaker which pareameters are γo=0, θ=65°, W=1.5 mm and
H=5 mm. Through above experimental results, the reasonable range of parameter θ can be proved.
 Fig. 18 Geometric relationship for solving parameter θ
In order to further verify reasonable range of parameter θ ∈(60°, 75°), cutting experiments were carried out
with the PCD tool with rake angle γo =0 and chip breaker parameter θ=45°, 50°, 55° and 60°, respectively. The
other parameters of the chip breaker were as follows: W = 1.5 mm and H=5 mm. Cutting parameters were as
follows: v c=800 m/min, ap=1 mm and f=0.2 mm/r. The experiment results are shown in Fig.19. When θ = 60°, the
chip can be broken normally during cutting operations, and chips are mostly C-type chips. When θ = 55°, the chip
breaking is in an unstable state. In Fig.19 (b), short spiral chips are generated, and sometimes long spiral chips are
formed which can not be broken. For θ=50° and 45°, continuous chips are randomly and disorderly wound around
the surface of workpiece and the cutting tool. According to above experimental results, if the chip can be broken
into C-type chips effectively, the inclination angel of chip breaker θ should not be less than 60°. By observing the
degree of the chip curling, we can find that the radius of chip curl curvature Rc gradually decreases as pareamter θ
increases. This observation is consistent with the simulated results shown in Fig. 8 (b).

（a）θ=60° （b）θ=55° （c）θ=50° （d）θ=45°

Fig. 19 Chips produced by tools with different θ values

4.3.3 Range of the position parameter W
Studies of Nakayama [48] show that the chip breaking effect of the chip breaker mainly depends on the radius
of chip curl curvature Rc, the chip thickness ach and the material properties of workpiece, as shown in Eq. (13). Since
the radius of chip curl curvature when the chip is reversely broken r2 is difficult to estimate, it is no easy to predict
whether the chip is broken by Eq. (13). Therefore, Eq. (13) needs to be transformed to convert difficult-to-calculate
parameters into easy-to-calculate parameters. The transformation process of Eq. (13) is as follows:
Eq. (13) is reciprocal and multiplied by π, we have
1 2 （20）
𝜀f ( 2 − 1)
let = , we have
2 2

𝜃1 1 （21）
𝜀f
̂ shown in Fig. 20. We have 𝜃1
Where, θ1r1 is the length of arc when the chip is broken, which is arc 𝐸𝑄 1
̂.
= 𝐸𝑄

Let 𝑅as = 𝜀 , then Eq.(21) can be written as

f

̂
𝐸𝑄
𝑅as （22）

Shinozuka et al [49] measured the size of chips and found that the ratio of the chip arc length 𝐸𝑄 ̂ to the chip
thickness ach is always less than a fixed value. The above research results can verify the Eq. (22). Therefore, we can
use Eq. (22) to predict chip breaking and to design a reasonable position parameter W of chip breaker. In Fig. 20,
point D is the tangent point between chip and rake face of tool, point E is the tangent point between chip and chip
̂ is the
breaker, AY is a horizontal straight line, SZ⊥AY, Lf is tool-chip contact length, ach is chip thickness, and 𝐸𝑄
arc length of chip from point E to point Q.

Fig. 20 Schematic diagram of geometric relationship for solving parameter W

̂ can be calculated as
In Fig. 20, the arc length 𝐸𝑄
̂ = 𝜃1
𝐸𝑄 (23)
According to geometric relationship in Fig. 20, we have
𝜃1 = − 𝐴1 𝐴𝑄 − 𝐴1 𝐴 − 1 (24)
where

𝐴1 𝐴 = (25)

𝐴𝐴1 (26)
𝐴1 𝐴𝑄 = arc cos

In order to calculate angle ∠A1AQ, it is necessary to solve line segment AA1 and the outer radius of chip curl
curvature r in Eq. (26). From Fig. 20, we have AA1=SZ, SZ=SD+DZ, then the calculation formula of AA1 is
AA1=SD+DZ (27)
where,
𝐷 = f cos − （28）
𝑆𝐷 = sin 𝑆𝐴𝐷 （29）
and
 （30）
𝑆𝐴𝐷 + 𝑆𝐷𝐴 =

（31）
𝑆𝐷𝐴 + =

Substituting Eq. (31) into Eq. (30), we have

𝑆𝐴𝐷 = （32）
The outer radius of chip curl curvature r is
𝐷𝐹𝐸 （33）
= 𝐷𝐹 tan

where,
𝐷𝐹 = − f （34）
𝐷𝐹𝐸 = − 𝜃 （35）
Substituting Eqs. (34) and (35) to Eq. (33), we have
−𝜃 （36）
=( − f ) tan

Substituting Eqs. (36) and (32) to Eq. (29), we have

−𝜃 （37）
𝑆𝐷 = ( − f ) tan sin

Substituting Eqs. (28) and (37) into Eq. (27), we have

−𝜃 （38）
1 = f cos − +( − f ) tan sin

Substituting Eqs. (36) and (38) into Eq. (26), we have

−𝜃 （39）
f cos − +( − f ) tan sin
𝐴1 𝐴𝑄 = arc cos
−𝜃
( − f ) tan

Substituting Eqs. (19), (25) and (39) into Eq. (24), we have
−𝜃 （40）
f cos − +( − f ) tan sin
𝜃1 = − arc cos −𝜃+
−𝜃
( − f ) tan

Iqbal et al [50] derived a formula for calculating the tool-chip contact length Lf
f = , (1 − tan ) + sec - （41）
（42）
where =

= sin 𝜅r （43）
Substituting Eqs. (23), (33), (40), (41), (42) and (43) into Eq. (22), we have
( 𝜅 , ( ) -) , ( ) - 𝜅
( 2 s 𝜅 , (1 ta ) s -) ta ( 𝑜 )
( 𝜅 , ( ) -)

𝑛𝜅

𝑅as (44)
3
Let sin 𝜅r , (1 − tan ) + sec - = a0 , tan = 0 and −𝜃+ = c0 , then we have
2 2

𝑅 sin𝜅r (45)
+ a0
a cos − sin 𝜅r
0 *c0 − arc cos (sin + 0 )+
0( − a0 )

For the convenience of calculation, we simplify the Eq. (45) to Eq. (46). The simplification process of Eq. (45) is
shown in the appendix.

(𝑅 sin𝜅r − a0 cos + sin 𝜅r ) (46)

( + a0 )
0 .c0 − + sin /

where, k is the correction factor, and we set k=0.907. The calculated process of correction factor k is also shown in
the appendix.
If position parameter of chip breaker W meets Eq. (46), the chip can be broken. For a given feed rate f*,
inequation W≤Wf* can be obtained according to Eq. (46). And according to our analysis in section 4.2.2, we have
W>Lf*. So, we can give the range of parameter W for effective chip breaking, Lf* <W ≤ Wf*. Fig. 21 is a schematic
diagram of range of parameter W for effective chip breaking. For example, given f=0.2 mm/r, ap=1 mm, θ=65°, H=5
mm. The other relevant parameters are γo=0 and κr =110°. Chip compression ratio ξ can be calculated according to
Eq. (42). We get an average value ξ=0.78 based pre-experiments. According to the study of Liu et al [51], we can
calculate the fracture strain εf of the 7075-T651 aluminum alloy, that is εf =0.109. So, we can have Ras=29, a0=3.31,
b0=1.57 and c0=3.58. According to Eq. (46), we can obtain the range of parameter W for effective chip breaking,
0.67 mm<W≤1.67 mm. Our results shown in Fig. 11 can provide a proof for this range of parameter W. In Fig. 11,
we set W=1.5 mm. Since 1.5∈(0.67, 1.67), Eq. (46) can be verified for f=0.2 mm/r. In order to further verify Eq.
(46), experiments with other feed rates were conducted, and results are listed in Table 4.

Fig. 21 Schematic diagram of the range of parameter W

 Table 4 Experimental results with different feed rates
Feed rate Range for chip breaking Experimental results
f（mm/r） Lf*＜W≤Wf*（mm） Within the range Outside the range

0.2 0.67＜W≤ 1.67

0.3 1.00＜W ≤2.50

0.4 1.34＜W ≤3.34

0.5 1.67＜W ≤4.17

4.3.4 Range of height H

In order to get good chip breaking performance of chip breaker, parameter height H of chip breaker should be
not less than effective height hef, that is, H ≥ hef. Effective height hef is shown in Fig. 18. In Fig. 18, point D is the
tangent point between chip and rake face of tool, line segment BC is parallel to the bottom edge of chip breaker IF,
intersects line segment EF at point E, and intersects line segment AD at point C. So we have hef=CD, AD⊥BC.
According to the geometric relationship shown in Fig. 18, we have

f = − 𝐴𝐶 (47)
where
𝐴𝐶 = cos 2 (48)
α2 in Eq. (48) can be calculated based on the quadrilateral ADFE

2 + 𝐴𝐷𝐹 + 𝐷𝐹𝐸 + 𝐹𝐸𝐴 = (49)

where
 𝐴𝐷𝐹 = (50)

𝐷𝐹𝐸 = −𝜃 (51)

𝐹𝐸𝐴 = (52)

Substituting Eqs. (50), (51) and (52) into Eq. (49), we have

2 =𝜃 (53)
Substituting Eqs. (36), (41), (48) and (53) into Eq. (47), we have
−𝜃 (54)
f =( − sin 𝜅r , (1 − tan ) + sec -) tan (1 − cos 𝜃)

In section 4.2.2, we have proved that the chip breaker with parameters θ=65°, W=1.5 mm and H=5 mm enabled
effective chip breaking. The other relevant parameters are as follows: f=0.2 mm/r, ap=1 mm, γo=0, κr=110° and
ξ=0.78. According to Eq. (54), the effective height of chip breaker can be calculated as hef=0.31 mm. Since H=5
mm>hef=0.31 mm, the theoretical calculation results are satisfied.
Through the above analysis of the effect of the chip breaker on chip breaking, we can summarize a design
method for chip breaker of PCD tool. Firstly, the calculation method of inclination angle θ is obtained in
consideration of the occurrence of chip cracks. Then, according to the criterion of chip breaking, the calculation
method of position parameter W is obtained. Finally, to ensure that the chip can touch chip breaker, the calculation
method of height H of chip breaker is obtained. So, we can get a simple set of equations for parameter design of chip
breaker of PCD tools, which includes Eqs. (19), (46) and (54).
The shape of chip breaker is determined by parameters θ and H. In Eq. (19), parameter θ is affected by the rake
angle of cutting tool, so the value of parameter θ can be determined based on rake angle of cutting tool. Given range
of the cutting parameters, the maximum effective height of chip breaking hefmax can be calculated by Eq. (54). The
height of chip breaker H only needs to satisfy H>hefmax. So, if cutting parameters are adjusted, the shape of chip
breaker does not need to be changed. We only need to adjust the position parameter of chip breaker W according to
Eq. (46) to obtain chip breaking under different cutting parameters.

In this study, an adjustable chip breaker is designed to expand the chip breaking range of cutting parameters for
PCD tools. Usually, most of the chip breaking conditions mainly include two types, one is that the chip touch the
workpiece, the other is that the chip touch tool shank. However, only first condition is considered in this study. We
set the chip breaker parallel to the equivalent cutting edge to allow chip to flow onto the workpiece. If a reasonable
angle between chip breaker and equivalent cutting edge is set, the chip may flow to tool shank. So, it is necessary to
investigate the influence of the angle between chip breaker and equivalent cutting edge on direction of chip flow and
chip breaking in further study.

5 Conclusions
An adjustable chip breaker is designed according to the structure and installation features of the PCD insert.
The position of the chip breaker on rake surface can be adjusted according to the variation of cutting parameters.
The influence mechanisms of inclination angle and the position parameter of chip breaker on chip curling are
obtained. There is a threshold for both inclination angle and the position parameter of the chip breaker. The
selected segment of chip which can be cracked and broken easily is determined. A simple set of equations are
derived for designing chip breaker parameters, including inclination angle, position parameter and height. A
design method for chip breaker parameters of PCD tool is presented. The application of the chip breaker can
expand the chip breaking range of cutting parameters for PCD tools.
Acknowledgements
This study was supported by National Natural Science Foundation of China (Grant No. 51875294) and
Ningbo Natural Science Foundation (Grant No. 2018A610153). This study was also sponsored by K.C. Wong
Magna Fund in Ningbo University.

Author statement

Maochao Wu: Conceptualization, Methodology, Software, Investigation, Data curation, Validation, Formal

analysis, Writing - original draft.

Aibing Yu: Conceptualization, Methodology, Formal analysis, Writing - review & editing， Supervision,

Project administration, Funding acquisition, Resources.

Qiujie Chen, Yanlin Wang, Jiandong Yuan, Lei Sun, Jianying Chi : Methodology, Investigation, Data curation,

Writing - review & editing.

Declaration of competing interests

The authors declare that they have no known competing financial interests or personal relationships that could have
appeared to influence the work reported in this paper.
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 Appendix

In Eq. (45), position parameter W appears on both sides of formula, especially, position parameter W is in the

arccosine function. So, it is not easy to calculate position parameter W. The Eq. (45) is

𝑅 sin r
+ a0
a cos − sin (A1)
0 *c0 − arc cos (sin + 0 r
)+
0( − a0 )

Eq. (A1) can be converted to

𝑅 sin r a0 cos − sin r

c0 − arc cos (sin + ) (A2)
0( − a0 ) 0( − a0 )

The Taylor’s formula of the arccosine function is given by

3
arc cos =2− − 6
+ ( ) 2
− (A3)

The right side of Eq. (A2) can be approximately expressed with the Taylor’s formula (A3). Then we get

𝑅 sin r a0 cos − sin r

c0 − − sin − (A4)
0( − a0 ) 0( − a0 )

Hence,

𝑅 sin r− a0 cos + sin r

c0 − + sin (A5)
0( − a0 )

3
In section 4.3.3, we have let −𝜃+ = c0 . So, c0 − 2 + sin . According to Eq. (A1), we can know
2

0( − a0 ) . So, Eq. (A5) can be written as

(𝑅 sin r − a0 cos + sin r)

+ a0 (A6)
0 .c0 − + sin /

In order to calculate the accuracy of Eq. (A6), we compared the calculated results of Eqs. (A1) and (A6) as

shown in Table A1. It can be seen that the calculated results of Eq. (A1) is smaller than those of Eq. (A6).
 Table A1. The range of W according to the calculation results of Eq. (A1) and Eq. (A6)

Difficult-to-calculate Eq. (A1) Easy-to-calculate Eq. (A6) Error

f (mm) 𝑅 sin r
+ a0
(𝑅 sin r − a 0 cos + sin r)
+ a0
a0 cos − sin r )+
Eq. ( 1) − Eq. ( 6)
0 *c0 − arc cos (sin + .c0 − + sin / | |%
0( − a0 ) 0 Eq. ( 1)

0.1 0.33＜ W ≤0.86 0.33＜ W ≤0.92 7.0%

0.2 0.67＜ W ≤1.72 0.67＜ W≤ 1.84 7.0%

0.3 1.00＜ W ≤2.56 1.00＜ W ≤2.76 7.8%

0.4 1.34＜ W ≤3.4 1.34＜ W ≤3.68 8.2%

0.5 1.67＜ W ≤4.21 1.67＜ W ≤4.60 9.3%

In order to improve the calculation accuracy of Eq. (A6) and to reduce the error between Eq. (A6) and Eq.

(A1), we add a correction factor k to Eq. (A6). So, we have

(𝑅 sin r − a0 cos + sin r) (A7)

( + a0 )
0 .c0 − + sin /

After above simplification process, we can get the Eq. (46), which is Eq. (A7) in Appendix.

In Table A1, the maximum error between the calculation results of Eq. (A1) and Eq. (A6) is 9.3%. So, we set

k=0.907 in this study.