Int. J. Machining and Machinability of Materials, Vol. 21, No.

4, 2019 245

On the curl and spring behaviour of CNC turned

beryllium copper chips using computational
image/video analysis

V.S. Sooraj*, Narayana Nidish, Anand Nikhil

and Chaudhary Priyanka
Department of Aerospace Engineering,
Indian Institute of Space Science and Technology (IIST),
Thiruvananthapuram, Kerala, 695547, India
Email: sooraj.iist@gmail.com
Email: nidbid@gmail.com
Email: Nikhil.myindia@gmail.com
Email: priyanka.aerospace@gmail.com
*Corresponding author

Abstract: Characteristic features of spring coiled chips generated during

straight turning of Beryllium-Copper alloy have been studied using
computational image and video analysis. Geometry and curl-behaviour of
ductile chips leading to the formation of continuous helical coil structure is
investigated theoretically and experimentally. Aiming the predictive generation
of such chips for futuristic applications, theoretical relationships are derived to
predict the curl radii and helix parameters in terms of cutting conditions and
tool geometry. Cutting performances are also analysed at various conditions
using the chip compression ratio, incorporating the inter-influence of major and
minor cutting edges. A specially designed vibration test of metal chip followed
by a computational video analysis is introduced in this work to assess their
spring characteristics and stiffness. A simplified spring-beam analogy is
applied for modelling the transverse vibration of chips using a clamped-free
end condition, frequency of which is analysed from the videos and correlated to
stiffness. Detailed experimental investigation followed by response surface
analysis is reported to illustrate the geometrical features of chips at various
cutting conditions.

Keywords: machining; beryllium-copper; chip; curl; spring; stiffness.

Reference to this paper should be made as follows: Sooraj, V.S., Nidish, N.,
Nikhil, A. and Priyanka, C. (2019) ‘On the curl and spring behaviour of CNC
turned beryllium copper chips using computational image/video analysis’,
Int. J. Machining and Machinability of Materials, Vol. 21, No. 4, pp.245–263.

Biographical notes: V.S. Sooraj is a faculty in the Department of Aerospace

Engineering, Indian Institute of Space Science and Technology (IIST). His
research interests include the development of micro finishing methodologies
for engineering surfaces, machining of aerospace materials, theoretical
modelling of cutting mechanics, and studies on additive fabrication.

Narayana Nidish received his Bachelor of Technology in Aerospace

Engineering from the Indian Institute of Space Science and Technology and
presently pursuing his Master’s. His topic of interest is in dynamics and
theoretical analysis of vibrations.

Copyright © 2019 Inderscience Enterprises Ltd.

246 V.S. Sooraj et al.

Anand Nikhil received his Bachelor of Technology in Aerospace Engineering

from the Indian Institute of Space Science and Technology and presently
occupied as a scientist in the Indian Space Research Organisation. His interest
and contribution include machining experiments and computational analysis.

Chaudhary Priyanka received her Bachelor of Technology in Aerospace

Engineering from the Indian Institute of Space Science and Technology and
presently occupied as a Scientist in the Indian Space Research Organisation.
Her interest and contribution include machining experiments and computational
analysis.

1 Introduction

Beryllium Copper (Be-Cu), the non-ferrous alloy known for its spring characteristics, is a
ductile material that can be machined easily. Turning of Be-Cu can produce large
continuous chips, like a coiled spring in its appearance and behaviour (Davis, 2001). The
health hazards associated with the machining of Be-Cu can be abandoned as the chip size
increases. However, machining operations that generates very small sized debris need to
be controlled with appropriate engineering and safety practices.
Experimental investigations on parametric optimisation during the machining of
Be-Cu are reported by various researchers. Assessment of optimum parameter levels for
controlled material removal and surface finish during the end milling of beryllium
copper, reported by Ramesh et al. (2014), is one of the recent works identified in this
area. Studies on machining characteristics and fracture morphologies of copper beryllium
(Cu-2Be) alloy by Sudhakar et al. (2006), presents a basic understanding on the
deformation mechanism and fracture during its interaction with polycrystalline diamond
cutter. The effect of cutting temperature on machinability of Cu-2Be is also addressed as
a part of this work. An experimental investigation on the machinability of Cu-Be alloys
during precision grinding and facing operation is reported by Hung et al. (1999). Effect of
process parameters, tool geometry and work piece microstructure on surface finish as
well as chip formation are reported while grinding Cu-Be using diamond wheels.
Mathematical model to predict the surface roughness after machining is also derived as a
part of this work.
A detailed explanation on the tribology of tool-chip and chip-work piece interfaces
during the machining of copper beryllium alloys and its comparison with other work
materials is done by Astakhov (2006). Based on the results shown, beryllium copper can
be considered as an excellent test material because of its flexibility to change mechanical
properties through heat treatment without significantly altering the phase composition
and micro structural parameters.
Research works are also focused on the non-traditional machining of
beryllium-copper, using electrical discharge machining, to address various engineering
applications (Rebelo et al., 2000). The effects of cryogenic treatments on such
non-traditional machining performances are also investigated (Yildiz et al., 2011). A
recent publication by Nobel et al. (2016) discussed the influence of material properties,
lead content and tool design on chip formation and chip curl radius, during the machining
of copper-Zn alloys. The prime focus was to study the behaviour of chip formation that
can lead to an optimal tool design for chip breaking.
 On the curl and spring behaviour of CNC turned beryllium copper chips 247

Shape and flow behaviour of metal chips were of key interest to many researchers for
analysing the mechanics and characteristics of machining operations. These studies were
basically focusing on product quality, surface generation, tool conditions, process
dynamics and control, etc. Machining Studies on Al/SiCp composites reported by Dabade
and Joshi (2009) was such an attempt to correlate the type of chip to the quality of work
surface. Numerical modelling and simulation of orthogonal machining reported by Boob
et al. (2015), finite element modelling and characterisation of chip curl in nose turning by
Devotta et al. (2017) and investigations on the effect of chip flow interference on cutting
force by Bi et al. (2014) are also found relevant in this regard. Chip morphology
prediction, chip flow-cutting force relationship, tool geometry-chip flow behaviour, etc.
are some of the key topics addressed in these articles.
While analysing the metal cutting dynamics and machine tool vibration, the major
dynamic systems include free movement of the tool, interaction of tool-and work piece
(rubbing, ploughing and cutting action of the tool), stick-slip effect at chip-tool interface,
etc. (Brandon et al., 2011). Cutting velocity, chip velocity, chip-tool friction coefficient,
chip contact length and chip stiffness are the significant factors associated with such
systems. In this context, it should be noted that the ‘chip stiffness’ can be considered as a
performance index to assess the dynamics of cutting. The present paper makes an attempt
of its first kind to study the stiffness of continuous chips produced during machining and
the effect of various process variables on it. In addition to the geometry of chips, stiffness
of chips is proposed as a machining characteristic that can be analysed systematically to
predict the machinability of materials. A computational video analysis is also proposed in
this paper to analyse the stiffness of chips in a simplified manner. This approach will be
useful in future machining studies to assess the dynamic behaviour of shearing and chip
flow, which could predict the ideal cutting conditions from the stiffness analysis of chips
produced during machining.
Some of the researchers attempted to have special tool configurations in turning
operations to control the chip shape and its flow for an improvised metal cutting
performance (Tomoya, 2016). Further, machining methods to produce chips of
predefined shapes and sizes by Mann et al. (2009) is a motivating research in the present
framework. It has been demonstrated that metal chips of varying size and shape,
including equiaxed particulates, ribbons, wires, filaments, needles, fibres, and platelets
can be produced by controlled modulation of cutting tools. The term ‘chip’ in this case is
generalised to any form that can be produced by a machining operation. Outcome of the
above research appears to be interesting and relevant while investigating the reusability
of chips from metal cutting. Shaw (2005) described a number of unusual applications of
metal cutting processes including the generation of thin magnesium foils and stainless
steel ribbons, by controlling the cutting conditions and tool geometry. Application of
turning operation using self-excited elastic tools to generate reusable steel fibres and the
effect of process variables on its geometry are also mentioned by Shaw (2005).
In this context, it was interesting to observe helical coiled-spring structured chips
while turning Be-Cu C17200 and the same has motivated the present research work.
Beryllium Copper is extensively used in the electrical industry to manufacture contact
parts in switching devices, such as fuzz buttons, spring probes, etc. The spring behaviour
of beryllium copper is the most significant and unique consideration in these cases. Even
though it is hypothetical, the possibility of generating spring coiled Be-Cu chips of
definite shape and controlled stiffness that can be re-used for similar futuristic
248 V.S. Sooraj et al.

applications are really interesting. As a preliminary step, it is intended to study the flow
of Be-Cu chips, its curling and geometrical characteristics at various cutting conditions.
Stiffness of continuous-spring-chip coil is also considered as a parameter for analysis
using a simple and unique chip testing procedure.

2 Methodology

Modelling of chip flow with curl, from the fundamental principles of metal cutting,
leading to the generation of helical-spring coiled chips during the machining of
copper-beryllium alloy C17200 has been addressed in detail. Machining experiments
were performed using CNC lathe to generate the chips and the images of these chips were
analysed using a sophisticated vision system to assess their geometric features. The curl
behaviour was modelled using the three dimensional chip flow kinematics considering
the comprehensive effects of tool geometry and cutting conditions. Characteristic features
of chips at various cutting conditions were examined using systematic experimental
investigation, supplementing the theoretical models considered. Computational image
analysis was applied to assess the curl and helix parameters of coiled chips.
Stiffness and spring characteristics of Be-Cu chips were performed using a specially
designed chip-vibration test followed by computational video analysis. To analyse the
spring behaviour, specially designed vibration test was performed on the helical coiled
chips generated at various cutting conditions. Computational video analysis using a high
speed camera, with the support of open-source software, was performed to yield the
transverse frequency mode of chip vibration. The output of frequency result was coupled
with the theoretical model to evaluate the stiffness of spring coiled chips.

3 Three dimensional modelling of chip-curl parameters

Chip compression ratio (CCR), the ratio of chip thickness to uncut thickness, is identified
as a classical parameter to quantify the total plastic deformation in metal cutting
(Astakhov, 2006; Shaw, 2005; Bhattacharya, 2004). According to Astakhov (2006), a
systematic measurement of CCR can directly reflect the final plastic deformation of chip
and it can be accounted as a prime parameter for optimisation of metal cutting process.
Further, velocity of chip flow (Vc) can also be represented as a function of CCR, using
the continuity equation;
Vc b 1
= (1)
V bc CCR
Here, it is expected that the cutting with velocity ‘V’ corresponding to an uncut thickness
‘t1’ and width of cut ‘b1’ will generate a chip of thickness tc and width bc.
While considering only the effect of principal cutting edge, the uncut thickness and
width of cut are represented as direct functions of feed (f) and depth of cut (ap),
respectively as
t1 = f sin K r (2)

and
 On the curl and spring behaviour of CNC turned beryllium copper chips 249

ap
b1 = (3)
sin K r
where Kr denotes the principal (major) cutting edge angle.
However, more realistic representation of chip flow kinematics is possible by
addressing the inter-influence of primary and auxiliary (minor) cutting edges. The
resultant chip flow, true uncut thickness and true width of cut are decided by the
orientation of equivalent cutting edge, which is again a function of major and minor
cutting edge angles. Based on selected tool-work configuration, the true uncut thickness
(t1T) and width of cut (b1T) can be calculated using the following equations, as discussed
by Astakhov (2010).
f c1
t1T = sin arctan (4)
c1 1 − e1 (1 − K r ) cot K r + e1 ( sin K r + g1 )

c1a p
b1T = (5)
c1
sin arctan
1 − e1 (1 − K r ) cot K r + e1 ( sin K r + g1 )

where

(
c1 = 1 − e1 1 − 1 − g12 , e1 =
rn
t1
and g1 =
f
2 rn
(6)

The above equations are reported to be valid for a tool with nose radius rn, auxiliary
(minor) cutting edge angle Kr1, operating within the feed and depth of cut limits as
indicated in the following equations;
a p ≥ rn (1 − cos K r ) and f ≤ 2 rn sin K r1 (7)

Though the chip is expected to flow perpendicular to the principal cutting edge in a free
cutting situation, the simultaneous action of both the cutting edges will make the effective
direction of chip flow perpendicular to the equivalent cutting edge (Astakhov, 2010). The
deviation angle ψ as indicated in Figure 1 can be evaluated using the following
expression (Bhattacharya, 2004).
sin ( K r + K r1 )
tan ψ = (8)
2a p
+ cos ( K r + K r1 )
f sin K r

The three-dimensional kinematics of chip curl while flowing over the rake face is shown
in Figure 2. According to this, the chip experiences curling about all the three axes,
namely up curling about X, side curling about Z and lateral curling about Y axis (Fang,
2002). The angular velocities associated with the curling are denoted by ωcurl-up, ωcurl-side
and ωcurl-lat respectively. All the three curling effects expected during the chip flow are
schematically shown in Figure 3.
250 V.S. Sooraj et al.

Figure 1 Geometry of chip flow

Figure 2 Geometry of chip curling

Figure 3 Schematics of side, up and lateral curl (see online version for colours)

From this, the angular velocity of side curl can be written as (Fang, 2002);
Vc
ωcurl − side = (9)
Rc ( side )
 On the curl and spring behaviour of CNC turned beryllium copper chips 251

where Rc(side) denotes the radius of side curl experienced by the chip. It can be represented
as a function of chip thickness (tc) and chip width (bc) using the chip side curl radius
equation
1  0.75 0.09  1
= − (10)
Rc ( side )  bc tc  κ

The term ‘k’ is defined as a modification coefficient, as discussed by Zhou et al. (2001).
1
In the present work, is evaluated empirically through a set of additional turning
κ
experiments on beryllium-copper at various feed and depth of cut.
Now ωR is considered as the resultant of all the three angular velocity components,
having included angle βx, βy and βz with X, Y and Z axes respectively, as in Figure 4.

Figure 4 Orientation of chip-curl angular velocities

Assuming a chip flow situation where the resultant angular velocity makes identical
included angle with all the three axes, the values of angular velocities ωcurl-up, ωcurl-side and
ωcurl-lat can be considered equal in magnitude.
From the three-dimensional kinematics of chip flow;
Vc cos ψ
ωcurl −up = (11)
Rc (up )

Since the angular velocity of side-curl and up-curl are considered to be equal,
Vc cos ψ
Rc (up ) = (12)
ωcurl −up

Substituting from equation (9),

Rc (up ) = Rc ( side ) cos ψ (13)

Similarly,
Vc sin ψ
Rc (lat ) = (14)
ωcurl −lat

Rc (lat ) = Rc ( side ) sin ψ (15)

252 V.S. Sooraj et al.

Since the angle of chip deviation (ψ) is normally very small, the radius of lateral curl will
be less significant in comparison with the side and up curl radius. In effect, the combined
effect of all these motions will make the chip flow like a helical coiled spring as shown in
Figure 5.

Figure 5 Macroscopic images and geometry of Be-Cu chips (see online version for colours)

From the fundamental geometric analysis, radius of helical coil (Rcoil) can be expressed as
(Bhattacharya, 2004),

1 − sin 2 ψ cos 2 β X
Rc ( coil ) = 2 2
(16)
 cos ψ   1 
R  + 
 c (up )   Rc ( side ) 

Applying equation (13) and simplifying further, radius of helical coil can be written as a
function of side curl radius (Rc(side)) and chip deviation angle (ψ)

1 − 0.33sin 2 ψ
Rc ( coil ) = Rc ( side) (17)
2
Similarly, the pitch of helix (P) can be expressed as (Bhattacharya, 2004)
2π Rcoil sin ψ cos β X
P= (18)
1 − sin 2 ψ cos 2 β X

Simplifying further and substituting from equation (17),

5
P= Rc ( side) sin ψ (19)
2
Knowing the values of diameter of helical coil and pitch, the helix angle λ can be
evaluated using the equation (20).

tan λ = P (20)
2π Rcoil

The above derived equations can predict the curl and helix parameters of spring-coiled
beryllium-copper chips in terms of input variables (feed, speed and depth of cut), and
cutting tool geometry.
 On the curl and spring behaviour of CNC turned beryllium copper chips 253

Further, the plastic strain associated with the free surface of chip (in its thickness
direction) during up-curling can be evaluated in terms of chip thickness and up-curl
radius using equation (21) (Buchkremer et al., 2014).

εcurl −up = tc (21)

2 Rc (up )

Similarly, plastic strain along the chip width corresponding to side-curl can be evaluated
as (Buchkremer et al., 2014).

εcurl − side = wc (22)

2 Rc ( side )

4 Theoretical model for spring stiffness analysis of coiled chips

To evaluate the axial stiffness of long spring shaped chips shown in Figure 5, the
response of such chips during transverse excitation is monitored. The methodology was
established by modelling the chip as a thin walled hollow beam and making an analogy
with beam vibrations. In the present model, the coiled chip is considered as a hollow
beam of circular cross-section with wall thickness tc (chip thickness), outer diameter Rcoil
(coil diameter), area of cross-section A, length L and Young’s modulus E.
From the above analogy, the stiffness of spring coiled chips (Ks) can be expressed
equivalent to the axial stiffness of beam as;
EA
Ks = (23)
L
If the spring-coiled Be-Cu chips are vibrated transversely, the equations of motion can be
written as (Blevins, 1979),
∂ 2 y EI ∂ 4 y
+ =0 (24)
∂t 2 ρA ∂x 4

where x, y and t denotes the axial position, transverse displacement and time variable
respectively. The term ρA represents the mass per unit length of chip under consideration.
The second moment of area in the bending axis (I) is given by
3
π ( 2 Rcoil ) tc 3
I= = 2 tc ( Rcoil ) (25)
4
The mode frequencies of such a transversely vibrating cantilever beam can be represented
as

1 αn EI
fn = (26)
2π L2 ρA

where αn = 3.52 for the first mode of frequency corresponding to clamped-free

(cantilever type) end conditions (Blevins, 1979).
In the present paper, computational analysis of videos captured during the transverse
vibration of spring coiled chips has been adopted to estimate the mode frequencies. For
254 V.S. Sooraj et al.

the known value of frequency, elastic modulus was calculated from equation (26) and
substituted back in equation (23) to get the stiffness value.

5 Details of experiments and measurements

Turning experiments were performed using a CNC lathe on Beryllium-Copper alloy

C17200 rods to generate spring-coiled chips at various cutting conditions. Table 1 shows
the composition and mechanical characteristics of selected alloy. The job diameter and
length of cut selected for the experiments were 25.4 mm and 100 mm.
Table 1 Characteristics of Be-Cu alloy used for experiments

Alloy type Be-Cu alloy C17200 used in aerospace applications,

manufactured as per the standard
ASTMB196/B196-07:C17200.
Composition (%) Be Cu Ni Fe Si Al Co
1.84 97.85 0.003 0.03 0.018 0.02 0.236
Density (kg/m3) 8,300
Elastic modulus (GPa) 131.32
Ultimate tensile strength (MPa) 1,254
Yield strength (MPa) 951
Hardness Rockwell C 40
Grain structure As per the specification of raw material considered, it
contains roughly equiaxed grains of copper and dispersion of
nickel, cobalt or nickel and cobalt beryllide particles. The
grain sizes are finer due to the aforementioned dispersion of
beryllides.

Table 2 shows the details of single point cutting tool used for turning operation.
Experiments were designed using a central composite-face centred cubic-pattern,
following the levels of process variables as indicated in Table 3. Each of these
experiments was replicated three times and additional experiments were also performed
at transitional levels to confirm the trends.
Table 2 Geometrical features of single point cutting tool

Tool material Coated carbide

Principal cutting edge angle (deg) 90
Clearance angle (deg) 7
Rake angle (deg) 0
Nose radius (mm) 0.4
Edge radius (µm) 25
Cutting edge length (mm) 09
Minor cutting edge angle (deg) 45
Condition of tool rake surface Flat and smooth
 On the curl and spring behaviour of CNC turned beryllium copper chips 255

Chips generated at various cutting conditions are systematically collected to evaluate chip
geometry, chip curl parameters and spring characteristics of chips. Size of chip, radius of
chip curl, pitch and diameter of helical coil, helix angle and spring constant of coiled
chips are the characteristic responses investigated. Influence of cutting parameters on the
output variables are analysed using response surface methodology and the results were
plotted using average values of responses.
Computer aided measurement of chip images, using a TESA vision system, was
preferred to evaluate their width, thickness, side curl radius, pitch of coil as well the coil
diameter. The up curl and lateral curl radii were estimated from the side-curl radius. CCR
was estimated using the measured chip thickness, at an uncut thickness t1 as per
equation (2), corresponding to the selected feed per revolution. CCR values were verified
using the weight measurement of straight chip segment as discussed in Astakhov (2006).
Revised CCR corresponding to the true uncut thickness (t1T) were also evaluated to
illustrate the effects of major and minor cutting edges.
Table 3 Selection of process variables

Parameter Low level (–1) Zero level (0) High level (+1)
Feed per revolution (mm/rev) 0.2 0.35 0.5
Cutting speed (m/min) 30 75 120

6 Evaluation of mode frequency by computational video analysis

For getting the frequencies, the spring shaped chips were vibrated transversely by
clamping at its one end. The response of this excitation was captured using a high speed
camera and analysed using open-source video processing software as shown in
Figure 6(a). A tracking sticker was attached at the free end of chip to facilitate the pattern
search in the software. Using the auto tracking feature of the software, the initial position
of free end is marked and saved as the template. After this, the software is set to search
for this template in each frame and mark through the video while the chip is vibrating. A
pixel-to-length ratio is established by calibrating the screen using a scale placed on the
backdrop as shown in Figure 6(b) and setting the coordinate frame. The software is used
further to generate data in the form of position (x, y) with respect to the origin. Same data
is extracted in the form of time series for the Y displacement after setting the axes
appropriately. Vibration experiments as well as video analysis were repeated (with
sufficient number of replications) on the chips collected at various cutting conditions and
fast Fourier transform (FFT) was applied on the data to get the power spectrum.
Figure 6(c) shows the power spectrum of such a sample data acquired using the proposed
video analysis. The first significant peak of power spectrum was identified to get the
required first mode frequency at the given experimental condition. This input was
plugged into equation (22), to get the elastic modulus (E).
256 V.S. Sooraj et al.

Figure 6 Video analysis of chip frequency (see online version for colours)

(b)

(a)

(c)

7 Results and discussions

7.1 Variation of side curl radius

Be-Cu rods of identical diameter were used for all the individual runs of experiments
presented in this paper. Since the diameter is same, increased level of cutting speed is
achieved by changing the rotational speed of work piece. An increase in cutting speed for
a fixed level of feed per revolution will effectively increase the feed rate of tool.
Thickness and width of chips observed at various cutting conditions are shown in
Figure 7. The CCR evaluated using uncut thickness and true uncut thickness (ξ and ξT) at
selected levels of process variables are indicated in the plot, supplemented by the
corresponding chip images. The combined effect of major and minor cutting edges,
effectively reducing the true uncut thickness due to the presence of equivalent cutting
edge, was reflected by the difference in CCR values.
Side curl radius of the chip was observed to be increasing with an increase in the level
of feed per revolution. It can be attributed to velocity gradient along the width of chip
during the increase in chip deviation. A thicker chip observed at high feed value, with
large deviation angle, will have a tendency to maintain more contact on the rake (XY)
surface and to have higher chip-tool contact. However, the effect of friction while a
thicker mass of chip flowing against the surface will enhance the tool-chip interface
temperature. High temperature at the bottom surface of chip and the temperature gradient
 On the curl and spring behaviour of CNC turned beryllium copper chips 257

with its free surface will make the chip curling in the upward and lateral direction. At
higher feed values, this counter effect of temperature is the reason for stabilised values of
side curl radius as shown in Figure 8.

Figure 7 Effect cutting parameters on chip dimension (see online version for colours)

Figure 8 Influence of feed on radius of side-curl (at cutting speed = 75 m/min) (see online
version for colours)

On the other hand, increase in cutting speed for a fixed value of feed will increase the
flow velocity of chip. High chip velocity in combination with an increase in chip
deviation angle may enhance the velocity gradient of chip in its width direction. In effect,
it will increase the side curl radius of the chip. However after a certain level of speed, the
magnitude of side curl radius were observed to be almost steady as shown in Figure 9. It
can be attributed to the effect of elevated cutting temperature expected at higher levels of
cutting speed as explained earlier. Influence of increased shear plane angle and reduced
chip thickness at higher levels of cutting speed, for a fixed value of feed per revolution,
may also be accredited to this. Curling tendency of chip in the upward and lateral
direction will be enhanced by these effects and thereby counteract on the rapid increase in
side-curl radius.
Variation of side curl radius calculated using equation (12) was showing a linearly
increasing trend against both feed as well as cutting speed. But the measured radii of side
curl were gradually stabilising at higher levels of cutting parameters. The dynamic effect
of chip velocity, chip deviation, shear plane angle and cutting temperature described
above can be accounted to explain this discrepancy. Considering all these, the measured
258 V.S. Sooraj et al.

value of side-curl radius is used further to explain the trends of up-curl, lateral curl, pitch
and diameter of helical coil associated with the chip flow.

Figure 9 Influence of cutting speed on radius of side-curl (at feed = 0.35 mm/rev) (see online
version for colours)

7.2 Variation of up-curl radius

As the cutting speed increases, the coefficient of friction at the chip tool interface gets
reduced. According to Ernst-Merchants theory (Bhattacharya, 2004; Shaw, 2005), shear
plane angle (based on thin shear zone model) get increased with a reduction in friction
angle for a fixed value of orthogonal rake angle. At higher values of shear plane angle,
chip thickness will be smaller. For a given feed (uncut thickness), a reduction in chip
thickness will enhance the cutting ratio. As the CCR decreases, the strain on the free
surface of chip gets reduced and will enhance the up-curling of chips (Bhattacharya,
2004; Buchkremer et al., 2014). At lower level of feed (0.2 mm/rev), up-curl radius was
showing gradually increasing trend with cutting speed, as shown in Figure 10, because of
the aforementioned effects.

Figure 10 Effect of cutting parameters on radius of up-curl (see online version for colours)

Up-curl radius shows an increasing trend with feed value at low level of cutting speed
(30 m/min), which was significantly dropping down at highest levels of feed. The
thickness, chip deviation angle and the side curl radius are expected to be higher at higher
 On the curl and spring behaviour of CNC turned beryllium copper chips 259

levels of feed values. While such a chip is gradually curling upward due to the effect of
temperature gradient in the direction of chip thickness (by the sliding effects in secondary
shear zone), it is expected to have an increased up-curl radius. However at highest levels
of feed (0.5 mm/rev), the up-curling becomes rapid due to the substantial effect of cutting
temperature. It will significantly reduce the radius of up-curling as shown in Figure 10,
which becomes more predominant at feed 0.5 mm/rev and cutting speed 120 m/min.

7.3 Variation of lateral-curl radius

Radius of lateral curl showed an increasing trend with feed rate as shown in Figure 11. It
is basically the effect of increased velocity gradient as well as temperature gradient at
higher feed rates. This can also be justified using equation (15), by the combined effect of
raise in side curl radius and chip deviation angle with feed rate.

Figure 11 Effect of cutting parameters on radius of lateral-curl (see online version for colours)

7.4 Variation of pitch and coil diameter

From equation (19), it is clear that the pitch of helical coiled chip increases with an
increase in side curl radius and chip deviation angle. The magnitudes of pitch measured
from the images of chips were also showing a growing trend in the beginning, but
gradually getting steady value at higher levels of cutting parameters as indicated in
Figure 12. It is simply correlated to the changes explained for side curl radius and chip
deviation angle at various cutting conditions. Similarly, the calculated and measured
values of chip coil diameters (as defined in Figure 5) at various cutting conditions are
indicated in Figure 13. At lower level of feed and cutting speed, chips were of helical
coiled shape with 8 to 12 mm diameter. With an increase in feed and cutting speed, the
observed chip coils were more open with an increased diameter. However, at higher
levels of cutting parameters, coil diameters were almost identical in magnitude as
indicated in the graph.
260 V.S. Sooraj et al.

Figure 12 Effect of cutting parameters on the pitch of helical coiled Be-Cu chips (see online
version for colours)

Figure 13 Effect of cutting parameters on the diameter of helical coiled Be-Cu chips (see online
version for colours)

Figure 14 Effect of cutting parameters on the helix angle of Be-Cu chips (see online version
for colours)
 On the curl and spring behaviour of CNC turned beryllium copper chips 261

It was also clear from the plots that the variation of pitch against feed per revolution is
steeper than that of coil diameter. While varying the feed at a given cutting speed, the
helix angle was observed to be increasing as shown in Figure 14. It was in close
agreement with the theoretical calculation of helix angle as a function of pitch and coil
diameter using equation (20). Sharp increase in pitch and relatively steady variation in
coil diameter, against the feed value, resulted in the increasing trend of helix angle at a
given cutting speed. However the helix angle versus cutting speed at a given feed per
revolution was almost constant, as expected from the trend of pitch and coil diameter.

7.5 Stiffness of spring coiled chips

Response surface showing the variation of stiffness calculated using the proposed
methodology, against the selected cutting parameters, is shown in Figure 15. Spring
shaped chips with lesser stiffness were observed at the middle ranges of cutting
parameters. It may be attributed to the combined effect of side-curl and up-curl, making
appropriate helical coiled (spring shaped) chips at the middle ranges of process variables.
Formation of thicker and more open coiled spring shapes at higher levels of feed rate was
increasing the stiffness as indicated. Based on the theoretical discussions in Sections 4
and 6, stiffness values can be correlated back to the geometry of chips and further to the
cutting performances such as CCR.

Figure 15 Effect of cutting parameters on the spring stiffness of Be-Cu chips (see online version
for colours)

To substantiate the results reported above, chip geometries were compared with those
generated by machining AISI 1088 steel using carbide tool (Fang, 2002). Even though
one to one comparison was not easy due to the difference in work materials, the range
and trends of observations (Table 4) were sensible to validate the theories proposed.
262 V.S. Sooraj et al.

Table 4 Comparison of steel and Be-Cu chips

AISI 1088 steel Be-Cu

Parameter Feed: 0.045 to 0.09 mm/rev. Feed: 0.2 to 0.5 mm/rev.
Cutting speed: 120 m/min Cutting speed: 30–120 m/min
Side curl radius 7.5 to 13.5 mm 5 to 10 mm
Pitch of helical coiled chip 5.9 to 6.5 mm 4 to 10 mm
Helix angle 21 to 27 10 to 18 mm

8 Conclusions

Through a methodical experimental and theoretical approach, the formation of spring

type-helical coiled chips during the straight turning of Be-Cu C17200 has been
investigated. The variation of curl radii corresponding to the side, up and lateral flow of
chips, leading to a continuous helical coiled structure is well illustrated through the
theoretical expressions derived. Pitch and coil diameter of spring type chip were observed
to be influenced significantly by the feed rate of cutting tool. Almost 66% increase in side
curl radius was observed while the feed per revolution is increased from 0.2 to 0.5
mm/rev, at a cutting speed of 75 m/min. Influence of cutting velocity, cutting temperature
and velocity gradient on the side curling of chips, leading to further curl in upward and
lateral direction to form the spring coil is discussed thoroughly. The results can be
applied to optimise the cutting condition and tool geometry selection to produce Be-Cu
chips of desired geometrical and spring characteristics. Plastic deformation quantified via
CCR during CNC turning of beryllium-copper alloy, incorporating the effects of true
uncut thickness, is also presented at various cutting conditions.
The transverse chip-vibration test combined with a computational video analysis to
assess the stiffness of spring coiled-continuous chip is a unique and simplified
methodology introduced in this research. In the present context, the relevance of stiffness
is to characterise the springy nature of beryllium-copper chip which may be useful while
analysing the futuristic functional applications of such chips. The first mode frequency
measured using chip-vibration video, plugged in the proposed theoretical model shown
an average stiffness of the order 0.3 N/mm within the selected levels of process variables.
Computational video analysis of chips highlighted in this work can be attempted as a
simplified strategy, on various other aerospace materials, to assess the dynamics of
material removal and chip flow behaviour. Plastic strain along the width and thickness
direction of chips can also be re-calculated from the geometry, curl and spring
characteristics of the chips.

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