A Training Brief from the Portable Machining Training Institute

Ch o o sin g the Right Cutting Tool

PartPart
2: 3
The Basics of Chip Formation
• During the machining process three basic types
of chips are formed:
o Discontinuous chips
o Continuous chips
o Continuous chips with a built-up edge (BUE)

• Discontinuous chips
o Typically associated with brittle metals like Cast Iron
o As feed is increased, some compression takes place
o As the chip starts up the chip-tool interference zone,
increased stress occurs until the metal reaches a
saturation point and fractures off the work-piece.
• Conditions which favor a discontinuous type of chip
o Brittle work material
o Small rake angles on cutting tools
o Coarse machining feeds
o Low cutting speeds
o Major disadvantage—could result in poor surface finish

Bringing the Solution to You.

Climax Portable Machine Tools, Inc. y 2712 E. Second Street y P.O. Box 1210 y Newberg, Oregon y 97132 y USA
Worldwide Telephone: 503.538.2185 y USA Toll-Free: 800.333.8311 y Fax: 503.538.7600 y Email: info@cpmt.com
Internet: www.cpmt.com
A Training Brief from the Portable Machining Training Institute

Ch o o sin g the Right Cutting Tool

Part 3
The Basics of Chip Formation
Continued

• Continuous Chips
o Continuous “ribbon” of metal that flows up
the chip/tool zone.
o Usually considered the ideal condition for
efficient cutting action.
• Conditions which favor a continuous type of chip:
o Ductile work
o Fine feeds
o Sharp cutting tools
o Larger rake angles
o Proper cutting speeds
o Proper coolants

Bringing the Solution to You.

Climax Portable Machine Tools, Inc. y 2712 E. Second Street y P.O. Box 1210 y Newberg, Oregon y 97132 y USA
Worldwide Telephone: 503.538.2185 y USA Toll-Free: 800.333.8311 y Fax: 503.538.7600 y Email: info@cpmt.com
Internet: www.cpmt.com
A Training Brief from the Portable Machining Training Institute

Ch o o sin g the Right Cutting Tool

Part 3
The Basics of Chip Formation
Continued

• Continuous chips with a built-up edge (BUE)

o Same process as continuous, but as the metal begins
to flow up the chip-tool zone, small particles of the
metal begin to adhere or weld themselves to the
edge of the cutting tool
o As the particles continue to weld to the tool it effects
the cutting action of the tool including the beginning
of gauling
• Conditions which favor a BUE type of chip:
o This type of chip is common in softer non-ferrous metals
and low carbon steel
o BUE chip formation increases as the tool begins to dull
• Problems associated with BUE chip formation
o Welded edges break off and can become
embedded in work-piece
o Decreases tool life
o Can result in poor surface finishes

Bringing the Solution to You.

Climax Portable Machine Tools, Inc. y 2712 E. Second Street y P.O. Box 1210 y Newberg, Oregon y 97132 y USA
Worldwide Telephone: 503.538.2185 y USA Toll-Free: 800.333.8311 y Fax: 503.538.7600 y Email: info@cpmt.com
Internet: www.cpmt.com