INTRODUCTION

• Carbon steel is a steel which contain carbon up to 2.1% by weight.

• Carbon steels are basically classified as three categories-

1.Mild or low-carbon steel,

2.High-tensile steel,

3.Higher-carbon steels.

• Mild steel (iron containing a small percentage of carbon, strong and tough but not readily tempered),
also called as plain-carbon steel or low-carbon steel.

• Mild steel is now the most common form of steel since its price is generally low while it provides
some outstanding material properties that are acceptable for many applications.

• Mild steel has a relatively low tensile strength compared to other carbon steel.

• But it is cheap and easy to form.

 INTRODUCTION
• Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a helix
toolpath by moving more or less linearly while the workpiece rotates.

• Generally the term "turning" is used to refer the generation of external surfaces by this cutting action.

• Whereas this same kind of cutting action when applied to internal surfaces, it is called as "boring".

• Turning can be mainly classified as straight turning, taper turning and external grooving.

• By performing chip analysis accordingly by varying different types of cutting conditions, we can able to
give a conclusion regarding different types of mechanical properties like ductility, strength etc.

• In our project work we are dealing at analysing different chips generated under different cutting
conditions of mild steel by turning operation and comparing with different chips generated under different
cutting conditions by varying composition of Al-Cu alloys micro alloying with Cd (varying from 0 to 0.1
wt%). Also to correlate surface roughness and cutting force value with the types of chips.
 LITERATURE REVIEW
SI. No. Title of the Paper Content of Paper

1. A Study on Chip Morphology of This work deals with chip

Aluminium Alloy 6063 during Morphology of Aluminium alloy 6063,
Turning under Pre Cooled in terms of chip types and chip
Cryogenic and Dry Environments. reduction coefficient in two different
environments.

2. Analysis of the dynamic chip In present the paper an attempt has

formation process in turning. been made to develop a complete
theory of the orthogonal metal cutting
process.

3. Characteristics of cutting forces In this paper, under different cutting

and chip formation in machining of speeds, feed rates and depths of cut,
titanium alloy. chip formation during dry turning of
Ti6Al4V alloy has been examined in
association with dynamic cutting force
measurements.
 LITERATURE REVIEW
4 Chip formation in The paper deals with the
monocrystalline iron-aluminium. thermomechanical mechanisms in the
material separation process and the
influences of the crystal lattice
orientation on the chip formation is also
analyzed in relation to the cutting
direction.
5. Chip Formation When Drilling This study aims to define and characterize
AISI 316L Stainless Steel using the different chips formation as a function
Carbide Twist Drill. of tool wear and cutting conditions in
drilling the stainless steel.
6. Experimental investigations on This work aims to investigate the varying
Chip Formation and Plowing contribution of chip formation and
Cutting plowing cutting forces at different
Forces during Hard Turning. cutting conditions during hard turning.
7. In this paper , the experimental results of
On the instability of chip flow in high-speed cutting on various typical
high-speed machining. metallic materials over wide ranges of
cutting speeds is analysed.
 LITERATURE REVIEW
8. On the mechanics of chip formation In this paper, finite element
in Ti–6Al–4V turning with spindle method(FEM )models of Ti–6Al–4V
speed variation. turning were set up to simulate both
spindle speed variation(SSV) and
constant speed machining(CSM).

9. Prediction of chip morphology and In this paper, a dynamic flow stress

segmentation during model based on high strain rate and
the machining of titanium alloys. high temperature, and a ductile fracture
criterion based on the strain energy are
applied to the crack initiation, also
compare this with experimental one.

10. Research on the Chip Formation This study investigated the process of
Mechanism during the high-speed chip generation and the change in chip
milling of hardened steel. morphology during the high-speed
milling of hardened steel.
 OBJECTIVE

• Turning operation is performed in mild steel with varying cutting condition.

• The images of the different type of chips captured using digital camera are visualised and inspected
to determine the effect of varying cutting parameters (cutting speed, feed and depth of cut) on the
type of chips formation.

• With the help of Ra and Rz data collected during machining operation, correlate the different type of
chips formation with surface roughness.

• Also by performing the inspection of the images of chips it is correlated it with cutting force data.

• Also compare these results based on turning operation performed on mild steel with previous chip
analysis result based facing operation on aluminium alloy.
 METHODOLOGY

• Analysis of chips of mild steel Alloy under varying Cutting Parameters(speed, feed and depth
of cut) by using digital camera.

• To analyse various chip type behaviour under varying cutting conditions.

• Turning operation (with varying cutting parameters of speed, feed and depth of cut) has been
performed on mild steel alloy .

• Chips generated from the above machining processes are taken up for the present study.

• All Chips will be properly processed and then wash with acetone and dried.

• With the help of good lighting arrangement different type of chips generated under varying
cutting parameters and microalloyed composition are placed in white paper.
 METHODOLOGY

• After that using a digital camera image of the different type of chips are captured.

• Then, the respective images are analysed to determine the effect of varying cutting condition
(cutting speed, feed and depth of cut) on the type of chips formation.

• With the help of Ra and Rz data collected during machining, correlate the different type of chips
formation with surface roughness and correlate the inspection of the images of different types of
chips with the mechanical properties with varying percentages (0 to 0.1 wt.%) of Cd.

• Compare mild steel chips generated by turning with 2219 Al-Cu alloy chips by varying cd wt.%
generated by facing.
 Speed(in rpm)
DoC Feed
114 325 550 930

S.R.= 123.87 S.R.=108.65 S.R.=91.29 S.R.=79.13

C.F=1.8 C.F=1.4 C.F=1.6 C.F=1.8
0.05

0.20

0.24 S.R.=306.92 Curly continuous chip with S.R.=296.62 S.R.=242.29 Curly continuous chip with
S.R.=182.61
small radius spiral big radius spiral
C.F=9 C.F=9 C.F=8.4 C.F=9.4

0.52
S.R.=488.13 S.R.=415.79 S.R.=337.33 S.R.=268.21
C.F=20.4 C.F=20.2 C.F=20.6 C.F=19.8

0.80 Curly continuous chip with Curly continuous chip with

S.R.=509.22 big radius spiral S.R.=457.58 S.R.=380.25 big radius spiral S.R.=342.14
C.F=30 C.F=30.4 C.F=30.2 C.F=29.8
 Speed(in rpm)
DoC Feed
114 325 550 930

S.R.= 254.15 S.R.=227.58 S.R.=161.94 S.R.=125.59

C.F=8.2 C.F=8.4 C.F=8.2 C.F=8
0.05

0.20
Non-Homogeneous and
Segmented chip
0.50 S.R.=389.54 S.R.=316.04 S.R.=227.40 continuous chip S.R.=202.30
C.F=24.8 C.F=24.2 C.F=24.4 C.F=24

0.52
S.R.=546.81 S.R.=481.23 S.R.=384.46 S.R.=299.40
C.F=41.2 C.F=41.6 C.F=40.8 C.F=40.2

Non-homogeneous and
0.80 Curly continuous chip with
S.R.=559.30 big radius spiral and with S.R.=504.33 S.R.=454.58 Curly continuous chip with S.R.=375.25
C.F=71.8 C.F=71.2 C.F=71.2 big radius spiral C.F=70.8
build up edge
 Speed(in rpm)
DoC Feed
114 325 550 930

S.R.= 435.60 S.R.=439 S.R.=297.75 S.R.=196.19

C.F=1.8 C.F=1.4 C.F=1.6 C.F=1.8
0.05

0.20

0.64 S.R.=455.95 Curly continuous chip with S.R.=391.40 S.R.=325.12

Curly continuous chip with
S.R.=281.02
small radius spiral big radius spiral
C.F=8.2 C.F=8.4 C.F=8.2 C.F=8

0.52
S.R.=581.09 S.R.=509.59 S.R.=424.65 S.R.=354.03
C.F=11.2 C.F=11.4 C.F=11.1 C.F=11

0.80 Curly continuous chip with Curly continuous chip with

S.R.=611.31 big radius spiral S.R.=542.48 S.R.=494.52 big radius spiral S.R.=431.46
C.F=15.2 C.F=15.4 C.F=15.8 C.F=15.2
 Speed(in rpm)
DoC Feed
114 325 550 930

S.R.= 123.87 S.R.=108.65 S.R.=91.29 S.R.=79.13

C.F=11.2 C.F=11.4 C.F=11.1 C.F=11
0.05

0.20

0.80 S.R.=306.92 Curly continuous chip with S.R.=296.62 S.R.=242.29 Curly continuous chip with
S.R.=182.61
small radius spiral big radius spiral
C.F=26.2 C.F=26.6 C.F=26.4 C.F=26

0.52
S.R.=488.13 S.R.=415.79 S.R.=337.33 S.R.=268.21
C.F=50.8 C.F=50.2 C.F=51.6 C.F=50.8

0.80 Curly continuous chip with Curly continuous chip with

S.R.=509.22 big radius spiral S.R.=457.58 S.R.=380.25 big radius spiral S.R.=342.14
C.F=73.6 C.F=73 C.F=73.2 C.F=72.8
 selected positions of
Given cutting
SI.NO Shapes and sizes of chips collected
condition and
Material composition
/ property

Low speed, Low

feed, Low DoC,
1 Curly continuous
chip with small
radius spiral chip

High speed, low

feed, low DoC, Curly
2 continuous chip
with big radius
spiral chip
 Low speed, High
3
feed, High DoC,
Discontinuous chip

High speed, High

4 feed, High DoC,
Continuous chip
with build-up edge

Medium speed,
5 Medium feed,
Medium DoC,
Continuous chip
 Cutting conditions and Detailed note on influence of given cutting condition and material composition /
Sl. Material composition properties on types of chips generated, SR, CF
No. & Properties

Low Medium High

Mainly discontinuous Medium size between curly continuous , continuous
continuous and discontinuous with build- up edge, non-
homogeneous continuous
Speed(with increasing
speed continuous type
(curly and build up edge
1 type) and non-
homogenous type chips
formation increases)
SR=559.3, C.F.=71.8 SR=454.58, C.F.=71.2 SR=375.25, C.F.=70.8
Mainly continuous Medium size between Mainly discontinuous
continuous and discontinuous
Feed(with increasing feed
chip curliness increases,
2 also with increasing its
value build up edge
formation increases)

SR=337.33, C.F.=20.6 SR=424.65, C.F.=51.6 SR=465.19, C.F.=60.8

 DoC(Basically with Mainly continous type Medium size between Mainly discontinous type
increasing depth of continuous and discontinuous
cut chip
fragmentation
increases and also
with its increasing
3 value build up
edge formation
getting increases) SR=337.33, C.F.=20.6 SR=424.65, C.F.=51.6 SR=465.19, C.F.=60.8
 CONCLUSION

• By visualising and inspecting digital images of turning chips of mild steel and comparing with facing chips of
Al-Cu alloy, it can be concluded that :

• In both case, with increasing cutting speed continuous chips formation increases. At low cutting speed,
formation of segmented chips increases.

• In both case, with increasing feed curly chips formation increases.

• In both case we found that , with increasing depth of cut segmented chip formation increases. While
decreasing it continuous chip formation increases.

• Different cutting condition basically influences surface finish achieved.

 CONCLUSION

• At low Ra and Rz value (optimum surface finish ) predominantly segmented chips are formed.

• While in case of Al alloy, one new chip which is not found in mild steel is also found ,named as saw-toothed
chips.

• At high Ra and Rz data curly and continuous chips are formed in both case, while only in mild steel
continuous chips with build up edge and non-homogenous chips are found.

• Also it is found that from the Ra and Rz data with increasing three cutting parameters (speed, feed and
depth of cut) surface roughness increases. But rate of increase of surface roughness in case of speed and
feed is relatively more than depth of cut.
 CONCLUSION

• By visualising more deeply, we found that continuous chips with BUE and non-homogeneous chips are found
only in case of mild steel under those cutting conditions, not in Al-Cu alloy chips. While saw toothed chips
only found in Al-Cu alloy chips.

• High feed, high speed and high depth of cut is the criteria for the formation of continuous chips with BUE.

• While in at high cutting speed non-homogenous chips are found.

• While saw-toothed chips are found in low feed, low speed and high feed.
FUTURE WORK
 Alloy A Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 12.87 S.R.=18.65 S.R.=26.99 S.R.=35.17

C.F=1 C.F=1 C.F=2 C.F=2
0.08

0.20
Curly continuous chip (start
0.20 S.R.=30.92 to curl
S.R.=26.62 S.R.=22.29 curly continuous chip S.R.=38.61
C.F=2 C.F=2 C.F=3 C.F=4

0.52
S.R.=48.31 S.R.=52.79 S.R.=37.77 S.R.=28.21
C.F=2 C.F=3 C.F=3 C.F=5

0.72 curly continuous chip

S.R.=50.22 S.R.=57.88 S.R.=80.25 curly continuous chip S.R.=42.14
C.F=3 C.F=3 C.F=4 C.F=7
 Alloy A Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 25.15 S.R.=27.58 S.R.=61.94 S.R.=52.59

C.F=2 C.F=2 C.F=3 C.F=3
0.08

0.20
Segmented chip Curly continuous chip
0.40 S.R.=39.54 S.R.=36.04 S.R.=27.80 S.R.=32.81
C.F=2 C.F=2 C.F=4 C.F=5

0.52
S.R.=56.81 S.R.=48.23 S.R.=34.46 S.R.=44.16
C.F=3 C.F=4 C.F=4 C.F=9

0.72
S.R.=59.30 Segmented chip S.R.=64.33 S.R.=71.70 Curly continuous chip S.R.=77.50
C.F=4 C.F=4 C.F=5 C.F=11
 Alloy A Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 35.60 S.R.=45.60 S.R.=58.22 S.R.=60.45

C.F=3 C.F=3 C.F=4 C.F=4
0.08

0.20
Segmented saw toothed Segmented saw toothed
0.60 S.R.=45.95 chip
S.R.=55.78 S.R.=64.87 chip
S.R.=74.85
C.F=3 C.F=4 C.F=5 C.F=7

0.52
S.R.=58.10 S.R.=65.19 S.R.=71.00 S.R.=74.87
C.F=4 C.F=5 C.F=6 C.F=14

0.72 Segmented saw toothed Curly continuous chip(start

S.R.=60.22 chip S.R.=65.66 S.R.=73.22 to curl) S.R.=75.46
C.F=5 C.F=5 C.F=6 C.F=17
 Alloy D Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 17.09 S.R.=18.65 S.R.=91.29 S.R.=79.13

C.F=2 C.F=3 C.F=4 C.F=5
0.08

0.20

0.20 S.R.=30.92 Segmented chip S.R.=26.62 S.R.=22.29 Long continuous chip S.R.=38.61
C.F=2 C.F=3 C.F=5 C.F=9

0.52
S.R.=48.31 S.R.=52.79 S.R.=37.77 S.R.=28.21
C.F=3 C.F=5 C.F=9 C.F=15

0.72 Long continuous chip

S.R.=50.22 S.R.=57.88 S.R.=80.25 Curly continuous chip S.R.=42.14
C.F=3 C.F=7 C.F=11 C.F=17
 Alloy D Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 25.15 S.R.=27.58 S.R.=61.94 S.R.=52.59

C.F=2 C.F=3 C.F=4 C.F=7
0.08

0.20

0.40 S.R.=39.54 Segmented chip S.R.=36.04 S.R.=27.80 Segmented chip S.R.=32.81

C.F=3 C.F=4 C.F=7 C.F=9

0.52
S.R.=56.81 S.R.=48.23 S.R.=34.46 S.R.=44.16
C.F=3 C.F=7 C.F=9 C.F=13

0.72 Segmented chip

S.R.=59.30 S.R.=64.33 S.R.=71.70 Curly continuous chip S.R.=77.50
C.F=4 C.F=7 C.F=11 C.F=19
 Alloy D Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 35.60 S.R.=45.60 S.R.=58.22 S.R.=60.45

C.F=3 C.F=5 C.F=7 C.F=9
0.08

0.20
Segmented chip Segmented chip
0.60 S.R.=45.95 S.R.=55.78 S.R.=64.87 S.R.=74.85
C.F=3 C.F=5 C.F=9 C.F=13

0.52
S.R.=58.10 S.R.=65.19 S.R.=87.17 S.R.=90.56
C.F=4 C.F=9 C.F=13 C.F=19

0.72
S.R.=60.22 Segmented chip S.R.=65.66 S.R.=73.22 Segmented chip S.R.=80.30
C.F=5 C.F=9 C.F=17 C.F=19
 Alloy F Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 26.98 S.R.=34.86 S.R.=33.47 S.R.=39.15

C.F=1 C.F=2 C.F=3 C.F=5
0.08

0.20
Segmented saw toothed
0.20 S.R.=25.15 chip
S.R.=27.58 S.R.=61.94 Curly continuous chip S.R.=52.59
C.F=1 C.F=2 C.F=5 C.F=7

0.52
S.R.=39.54 S.R.=36.04 S.R.=27.80 S.R.=32.81
C.F=2 C.F=3 C.F=7 C.F=9

0.72 Curly continuous chip

S.R.=56.81 S.R.=48.23 S.R.=34.46 Curly continuous chip S.R.=44.16
C.F=2 C.F=4 C.F=9 C.F=13
 Alloy F Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 25.15 S.R.=27.58 S.R.=61.94 S.R.=52.59

C.F=2 C.F=4 C.F=5 C.F=7
0.08

0.20
Segmented saw toothed
0.40 S.R.=39.54 chip
S.R.=36.04 S.R.=27.80 Curly continuous chip S.R.=32.81
C.F=2 C.F=4 C.F=7 C.F=9

0.52
S.R.=56.81 S.R.=48.23 S.R.=34.46 S.R.=44.16
C.F=3 C.F=5 C.F=9 C.F=11

0.72 Saw toothed chip (just start

S.R.=59.30 to curl) S.R.=64.33 S.R.=71.70 Curly continuous chip S.R.=77.50
C.F=3 C.F=5 C.F=11 C.F=13
 Alloy F Speed(in rpm)
DoC Feed
192 325 495 550

S.R.= 35.60 S.R.=45.60 S.R.=58.22 S.R.=60.45

C.F=3 C.F=5 C.F=7 C.F=9
0.08

0.20
Segmented saw toothed
0.60 S.R.=45.95 Segmented chip S.R.=55.78 S.R.=64.87 chip
S.R.=74.85
C.F=3 C.F=5 C.F=9 C.F=11

0.52
S.R.=58.10 S.R.=65.19 S.R.=87.17 S.R.=90.56
C.F=4 C.F=6 C.F=11 C.F=15

0.72 Segmented saw toothed

S.R.=60.22 chip S.R.=65.66 S.R.=69.13 Curly continuous chip S.R.=71.30
C.F=4 C.F=7 C.F=13 C.F=19
 selected positions of
Given cutting
SI.NO Shapes and sizes of chips collected
condition and
Material composition
/ property

Low speed, Low

feed, Low DoC,
1 Alloy A
Segmented and saw
toothed chip
Etc.

High speed ,Low

feed , Low DoC,
2 Alloy A
Curly continuous
chip etc.
 Low speed ,High
3
feed ,High DoC,
Alloy A
Curly continuous
chip etc.

High speed, high

4 feed, high DoC,
Alloy A
Curly continuous
chip

Medium speed,
medium feed,
5 medium depth of
cut, Alloy A
Continuous chip
 Cutting conditions and Detailed note on influence of given cutting condition and material composition /
Sl. Material composition properties on types of chips generated, SR, CF
No. & Properties

Low Medium High

Segmented chip Medium size between Continuous type
segmented and continuous type

Speed(with increasing
speed chip continuity
increases)
1

SR=48.31, C.F.=2 SR=37.77, C.F.=3 SR=28.21, C.F.=3

Segmented type Medium size between Curly continuous
segmented and curly continuous
Feed(with increasing feed
type
chip curliness increases)
2

SR=35.17, C.F.=5 SR=38.61, C.F.=7 SR=42.14, C.F.=13

 DoC(with continuous type Medium size between Segmented type
increasing depth of continuous and segmented
cut chip type
fragmentation
increases)

SR=50.22, C.F.=3 SR=59.3, C.F.=4 SR=60.22, C.F.=5

Sl. No. Types of Chips Detailed note on correlation with: Cutting conditions
Material composition & Properties- S.R. and C.F.

Types of Cutting conditions: at low speed, low feed, high depth of cut such type of chips are
mainly found.
1 Types of Material composition / Properties: Alloy A
General SR on such conditions: surface roughness found to be low, so optimum surface finish
achieved.
General CF on such conditions:

Types of Cutting conditions: at high feed, high speed, low depth of cut such type of chips are
mainly found.
2 Types of Material composition / Properties: Alloy A
General SR on such conditions: surface roughness is generally high, so rough surface finish
achieved.

Types of Cutting conditions: at low speed, low feed, high depth of cut such type of chips are
3 mainly found.
Types of Material composition / Properties: Alloy A

General SR on such conditions: surface roughness is low, so optimum surface finish achieved.
General CF on such conditions: