Mechanism of Chip Formation

By
Dr. Kazi Sabiruddin
IIT Indore
Why chip (form/colour etc.) is important?
[In machining excess material from preform blank is removed in the form of chip]

We can estimate the following by observing the

form/shape/colour of a chip:

1. Nature and behavior of work material

2. Specific energy requirement for the machining

3. Nature and degree of interaction at work-tool interfaces

Decision: Favorable machining/Non-favorable machining

 Form and Colour of a chip depend on
• Work material
 Brittle: Broken/discontinuous chips (small)
 Ductile: Continuous (long)

• Cutting tool material

 Chemically inert: smooth chips
 Chemically active towards work: rough chips

• Levels of process parameters

 Cutting velocity (Vc): temperature rise and dark colour
 Feed rate (So): temperature rise and dark colour

• Application of cutting fluid

 with proper cooling and lubrication favorable chips form
 Mechanism of chip formation:
Ductile work material

Yielding

Compression of work material ahead of the tool tip

Result: Shear along the shear plane
Better explained by: Piispanen Model
Card and Board analogy

Cards Board

Tool

Work
Increase in chip thickness: Experiments

c) Offline microscopic study of frozen chips

d) Online study of forming chips by high speed camera

 Mechanism of chip formation:
Brittle work material
Steps:
1. Crack initiation at stress
concentration zone (tool tip) Crack
Initial small
crack propagation
2. Propagation of crack (s)

3. Swelling

4. Separation of chips

Brittle
Fracture
 Geometric characteristics of
Continuous Chips (ductile work)
a1 = Uncut chip thickness
a2 = Chip thickness
b1 = Uncut chip width
b2 = Chip width
A1 = Cross sectional area of
chip before cut

Vc = Cutting velocity (m/min),

so = Feed rate (mm/rev)
t = Depth of cut (mm)
N = Rotational speed (RPM)
For cylindrical job, if outer diameter of job is D (mm)

Then, Vc = πDN/1000 (m/min)

 How to find the value of
a1 (uncut chip thickness)?

AB = so

BO is perpendicular to AO

BO = a1
Angle BAO = φ (ORS)

Sin φ = BO/AB
= a1 / so

a1 = so Sin φ (mm)
 Chip Reduction Co-efficient (ζ)
Index to judge the chip thickening
ζ = a2 /a1 (ζ > 1 as a2 > a1)

Cutting Ratio r = 1/ζ < 1

Less ζ Less thickening Less energy investment

Kronenberg’s Model (for orthogonal cutting):

ζ depends on:

a1 = Uncut chip thickness

* π/2 and γ are in radians
a2 = Chip thickness,
μ = Co-efficient of friction on rake surface
γo = Orthogonal rake angle
So = Feed rate
φ = Principal cutting edge angle
Vc = Cutting velocity
Vf = Chip flowing velocity
 How to reduce ζ?
To perform same machining operation with lesser energy investment

• Use of high orthogonal rake angle

(has some limitations considering other factors)

• Use of lubrication at tool-work contact

Roles of rake angle and co-efficient of friction on ζ

 How to find Shear Angle (βo)?
Angle AOD = (90o – βo)

Angle AOC = Angle AOD + γo = (90o – βo + γo)

Angle CAO = 90o - (90o – βo + γo) = (βo – γo)

AB = a1= OA Sin βo and AC = a2 = OA Cos (βo - γo)

a2 /a1 = ζ= Cos (βo - γo)/ Sin βo

ζ = (Cos βo Cos γo + Sin βo Sin γo)/Sin βo

Cot βo = (ζ - Sin γo)/ Cos γo

βo = f (ζ , γo)
 How to find Shear Strain (ε)?
Recap

τs = Total shear stress

Δs = Amount of shear/shift

y = Height of shear plane/

perpendicular distance between planes

Shear strain ε = Δs/y = tan θ

Δs = MN
ε = MN/OP
y = OP
 Shear Strain calculation
ε = MN/OP
= (MP + PN)/OP [as, MN= MP+PN]

MP = OP Cot βo

PN = OP tan (βo – γo) [as, angle PON = βo – γo]

ε = OP [Cot βo + tan (βo – γo)]/OP

ε = Cot βo + tan (βo – γo)

ε should be as low as possible to minimize the cutting temperature

Built-up-edge (BUE) formation

At secondary deformation zone (for ductile materials):

(1) High stress and (2) High temperature

Result:
BUE
Local welding/adhesion between the nascent
surfaces of tool tip and work.

* Up to a certain size the BUE can withstand the

compressive stress of flowing chips. On reaching to a
critical size the BUE separates from the tool and is
carried away with the under surface of chip.
 Characteristics of BUE
The shape, size and bond strength of BUE depend on:

 Tool – work materials

• Inert tool: No BUE
• Ductile work with continuous chip: More BUE

 Tool geometry
• -Ve tool: More BUE

 Stress and temperature at contact zone

• High stress: More BUE
• High stress: More BUE

 Cutting fluid application

• Lubrication: Less BUE
• Cooling: Less BUE
 Effects of BUE
1. Unfavorable rake angle and consequences
 More ζ
-Ve rake
 More energy investment

 More power consumption

+Ve rake
 More temperature etc.

2. Fluctuation of cutting forces and consequences

 Damage of tool

 Damage of work surface

 Damage of the health of machine tool

 Effects of BUE cont.
3. BUE on flank and poor surface finish

4. Reduced tool life by tool wear

Roles of Process Parameters on BUE
Thank You