Chip Formation

Four Basic Type of Chips in Machining are:

• Discontinuous chip
• Continuous chip
• Continuous chip with Built-up Edge (BUE)
• Serrated chip
 Chip Formation
Discontinuous chip
When brittle materials like cast iron are cut, the deformed material gets
fractured very easily and thus the Chip produced is in the form of
discontinuous segments.
Reasons
• Brittle work materials
• Low cutting speeds
• Large feed and depth of cut
• High tool-chip friction
 Chip Formation
Continuous chip
Continuous chips are normally produced when machining steel or ductile
materials at high cutting speeds. The continuous chip which is like a
ribbon flows along the rake face.
Reasons
• Ductile work materials
• High cutting speeds
• Small feeds and depths
• Sharp cutting edge
• Low tool-chip friction
 Chip Formation
Continuous chip with Built-up Edge (BUE)
When the friction between tool and chip is high while machining ductile
materials, some particles of chip adhere to the tool rake face near the tool
tip is termed as built up edge (BUE). By virtue of work hardening, BUE is
harder than the parent work material.
Reasons
• Ductile materials
• Low-to-medium cutting speeds
• Tool-chip friction causes portions of
Chip to adhere to rake face
• BUE forms, then breaks off, cyclically
 Characteristics of BUE
Built-up-edges are characterized by its shape, size and bond
strength, which depend upon:
• work tool materials
• stress and temperature, i.e., cutting velocity and feed
• cutting fluid application governing cooling and lubrication.
BUE may develop basically in three different shapes as
schematically shown.
 Effects of BUE Formation

Formation of BUE causes several harmful effects, such as:

• It unfavorably changes the rake angle at the tool tip causing

increase in cutting forces and power consumption.

• Repeated formation of the BUE causes fluctuation in cutting

forces and thus induces vibration which is harmful for the tool, job
and the machine tool.

• Surface finish gets deteriorated.

• May reduce tool life by accelerating tool-wear at its rake surface.

Cutting Speed v/s Surface Roughness
Orthogonal cutting & Oblique cutting
 Heat generation in metal cutting

1.Primary shear zone - Where the major part of the energy is converted into
heat.
2. Secondary deformation zone - At the chip – tool interface where further
heat is generated due to rubbing and / or shear.
3.Teritiary deformation zone- At the worn out flanks due to rubbing between
the tool and the finished surfaces.
Merchant model for Orthogonal cutting

Forces acting on chip during metal cutting

Merchant model for Orthogonal cutting

Merchant circle diagram

Merchant model for Orthogonal cutting

Merchant circle diagram showing various angles

Merchant model for Orthogonal cutting

Merchant circle diagram showing various angles

Shear angle relationship in terms of chip thickness ratio
& rake angle

Chip formation process