MECHANISM FORMATION

ABSTRACT:

OF

CHIP

It is known from the theory of metal cutting that an examination of machining chips provides the cheapest and the most effective way of understanding the machining characteristics of a material. The review of literature on machining of metal reveals that these aspects have been given relatively little attention during the machining studies. This viewpoint has provided motivation for the study of fundamental aspects of machining of composites involving chip formation mechanism experimentally and analytically. This paper discusses experimental work and finite element analysis to investigate the mechanism of chip formation during machining of metal. Focus of this paper is on understanding the influence of different cutting parameters on mechanism of machining. Chips generated experimentally and by finite element modeling during orthogonal machining of metal were used for this purpose.

1. INTRODUCTION
Chip formation is part of the process of cutting materials by mechanical means, using tools such as saws, lathes and milling cutters. An understanding of the theory and engineering of this formation is an important part of the development of such machines and their cutting tools. Chip formation is usually described according to a three-way model developed by Franz. This model is best known within the field of machine tool design, although it is also used when an

Page 1 of 6

application area, such as woodworking, requires a vocabulary to describe chip formation in more detail than is usually attempted Below is illustrated the basic geometry of two-dimensional chip formation. The model is twodimensional for simplicity.

The material immediately in front of the tool is bent upward and is compressed in a narrow zone of shear which is shaded on the drawing above. For most analyses, this shear area can be simplified to a plane. As the tool moves forward, the material ahead of the tool passes through this shear plane. If the material is ductile, fracture will not occur and the chip will be in the form of a continuous ribbon. If the material is brittle, the chip will periodically fracture and separate chips will be formed. It is within the shear zone that gross deformation of the material takes place which allows the chips to be removed. As on the stress-strain diagram of a metal, the elastic deformation is followed by plastic deformation. The material ultimately must yield in shear. The figure depicts the cutting area in terms of lines of Page 2 of 6

flow. As the material flows from the bulk of the work piece to the shear area, it is violently sheared, and then continues into the chip section.

2. TYPES OF CHIPS:
Chips are formed due to cutting tool, which is harder and more wearer-resistant than the work piece and the force and power to overcome the resistance of work material. The chip is formed by the deformation of the metal lying ahead of the cutting edge by a process of shear. Four main categories of chips are: Discontinuous Chips Continuous or Ribbon Type Chips Continuous Chip Built-up-Edge (BUE) Serrated Chips

2.1 Discontinuous Chips These chips are small segments, which adhere loosely to each other. They are formed when the amount of deformation to which chips undergo is limited by repeated fracturing. Hard and brittle materials like bronze, brass and cast iron will produce such chips. 2.2 Continuous or Ribbon Type Chips In continuous chip formation, the pressure of the work piece builds until the material fails by slip along the plane. The inside on the chip displays steps produced by the intermittent slip, but the outside is very smooth. It has its elements bonded together in the form of long coils and is formed by the continuous plastic deformation of material without fracture ahead of the cutting edge of the tool and is followed by the smooth flow of chip up the tool face

Page 3 of 6

2.3 Continuous Chip Built Up Edge This type of chip is very similar to that of continuous type, with the difference that it is not as smooth as the previous one. This type of chip is associated with poor surface finish, but protects the cutting edge from wear due to movement of chips and the action of heat causing the increase in tool life. 2.4 Serrated Chips These chips are semi continuous in the sense that they possess a saw-tooth appearance that is produced by a cyclical chip formation of alternating high shear strain followed by low shear strain. This chip is most closely associated with certain difficult-to-machine metals such as titanium alloys, nickel-base super alloys, and austenitic stainless steels when they are machined at higher cutting speeds. However, the phenomenon is also found with more common work metals (e.g., steels), when they are cut at high speeds.

3. CHIP FORMATION IN METAL MACHINING:

Since the practical machining is complex we use orthogonal cutting model to explain the mechanics. In this model we used wedge shaped tool. As the tool forced into the material the chip is formed by shear deformation. The figure depicts an idealized, two dimensional view of the metal cutting process. The assumptions in this model are that the tool is perfectly sharp, that the cut depth and the cutting speed are constant, and that the cut depth is small compared to the cut width. In this idealized model, the material layer at the top is formed into a chip by a shearing process in the primary shear zone . The chip slides up the rake face undergoing some secondary plastic flow due to the forces of friction. This idealized model correctly predicts that cutting force Page 4 of 6

increases with cut depth, material hardness, and friction coefficient. Cutting forces are inversely proportional to rake angle. Power required increases with the feed rate.

4. DEFORMATION OF UNCUT LAYER:

The problem in the study of the mechanism of chip formation is the deformation process of the chip ahead of the cutting tool. It is difficult to apply equation of plasticity as the deformations in metal cutting are very large. Experimental techniques have always been resorted to for analyzing the deformation process of chips. Several methods have been used:

Taking photographs of the side surface of the chip with a high speed movie camera fitted with microscope.

Observing the grid deformation (directly)

o On the side surface of the work piece and o On the inner surface of a compound work piece.

Examination of frozen chip samples taken by

o Drop tool apparatus and o Quick stop apparatus Page 5 of 6

5. CONCLUSION
As a conclusion for the study of the chips formation which are continuous, discontinuous, and built up age chips. The formation of the chips depend on the cutting speed, feed rate, cutting speed and cutting fluid. The cutting fluid is a big factor to the chip formation where if the cutting process is done without the cutting fluid, the chip results in blue and black color. This show that cutting fluid have many effects on chip formation.

6. REFERENCES:
Manufacturing science II , K.M. Moeed Serope Kalpakjian and Steven R. Schmid, Manufacturing Engineering and Technology, 4th Edition, Prentice Hall, 2001 http://www.scribd.com/doc/35912796/Chip-Formation http://www.scribd.com/doc/78223821/Study-on-Modeling-of-Chip-Formation http://en.wikipedia.org/wiki/Chip_formation http://www.sandvik.coromant.com/engb/knowledge/milling/getting_started/general_guidelines/chip_formation/pages/default. aspx http://electron.mit.edu/~gsteele/mirrors/www.nmis.org/EducationTraining/machinesho p/physics/intro.html

Page 6 of 6