Experimental Study on BUE Formation

Experimental Study on role of tool-work materials and
machining condition on Built up edge formation
Project: Part-II (ME-882)
Submitted in partial fulfillment of the requirement for the degree

of
B.TECH in Mechanical Engineering 2013-2017
By
SK. ANISH AHAMED SOUMYAJIT DAS

(16900713102) (16900713105)
SOUMYA GUHA SUMAN SAHA
(16900713103) (16900713116)
Under the guidance of:-
Prof. A. B. Chattopadhyay
Mechanical Engineering Department
Academy of Technology
G.T. Road, Adisaptagram, P.O : Aedconagar
Hooghly-712121, West Bengal
2017
PROJECT PART - II PAPER NAME - ME- 882
CERTIFICATE OF RECOMMENDATION
This is to certify that the project entitled Experimental study on Geometry, causes effects and
control of Built-Up Edge (BUE) formation in turning on C30 steel by HSS and carbide (both
un-coated & coated) inserts under different conditions (tools, velocity, feed & environment).
Which is being submitted by Sk Anish Ahamed(16900713102), Soumya Guha(16900713103),
Soumyajit Das(16900713105), Suman Saha(16900713116). In partial fulfillment for the award
of Degree of Bachelor of Technology in Mechanical Engineering to Academy of Technology,
Hooghly-712121 under MAKAUT during the academic year 2013-2017 is the record of
students work carried by us under the guidance of Prof. A.B.Chottopadhyay.
. Examiner(s) Signature
Prof. A.B.Chattopadhyay
[Supervisor] .
Department of Mechanical Engineering
..
Countersigned by
..
.
[Head]
Prof. Amit Kumar Rana
Department of Mechanical Engineering
STATEMENT BY THE CANDIDATE
We hereby state that this technical report has been prepared by us , is a record of our
presentation on this topic (Experimental Study on the role of tool-work materials and
machining condition on Built up edge formation). The report is being submitted to
fulfill the requirements of course ME- 781 of the curriculum of AOT, Adisaptagram,
Hooghly, India-712121.
..................................... .....................................
SOUMYA GUHA SOUMYAJIT DAS
(1690713103) (16900713105)
.................................. ...................................
SUMAN SAHA SK. ANISH AHAMED
(16900713116) (16900713102)
ACKNOWLDGEMENT
I am thankful to my guide Prof. A.B. Chattopadhyay whose personal enrollment in the

technical seminar presentation and the report has been a major source of inspiration
for me to be flexible in my approach and thinking of tackling the various issue. He
assumes the critical role of ensuring that I am always on the right track.
I also extend my gratitude to Prof. A.K.Rana without whose support, co-operation and
guidance this paper presentation would not have been a success.
Last but not the least we would like to say a big thanks to all the staff of Mechanical
Department.
CONTENTS
1. List of Symbols 6
2. List of Tables 7
3. CHAPTER-1
3.1 Introduction 10
3.2 What is Built-Up Edge 11
3.3 Tool-Chip Friction and Secondary Deformation 14
3.4 Formation Of Chip 15
3.5 Mechanism Of BUE 16
3.6 Using The BUE 18
3.7 Factors influencing BUE 19
3.8 Analysis of Evolution and Formation of BUE layer 22
3.9 Effects of BUE 23
3.10 Necessary Condition for showing BUE 25
3.11 Reduction of BUE 26
3.12 Conclusion 27
4. CHAPTER-2
4.1 Project Outline 29
4.2 Material C30 , Tool- Coated Carbide, Condition Dry
4.2.1 Chip table 30
4.2.2 Chip reduction co-efficient vs. cutting velocity graph 31
4.2.3 Force measurement graph, cutting force vs. time 32
4.3 Material C30 , Tool- Coated Carbide, Condition Flood
4.3.1 Chip table 36
4.4 Material C30 , Tool- Uncoated Carbide, Condition Flood
4.4.1 Chip table 42
4.5 Material C30 , Tool- Uncoated Carbide, Condition Dry
4.5.1 Chip table 47
5. Conclusion 53
6. References 54
List of Symbols :-
a1 Chip thickness before cut e effective clearance angle

a2 Chip thickness after cut n normal clearance angle
C Constant in Taylor tool life equation r radial clearance angle
D Diameter of a work-piece s side clearance angle
f Form Factor friction angle on tool face = tan-1
s0 feed per revolution (FC/NC)
t Required time rake angle
N r.p.m. c temperature (fundamental

dimension in dimensional analysis)
Vc cutting speed
co-efficient of tool-face friction
P Cutting force tan = FC/NC
N Normal force e effective friction coefficient
Tc cutting time Shear stress
b back clearance angle angular velocity (rad s-1)
Principle Cutting angle Chip reduction ratio
List Of Figures:-
1. Formation of Built-Up Edge
2. Scheme of BUE growth and shearing parts
3. Location of BUE formation
4. Growth of BUE formation(Embryo)
5. Gradual chip removal and detoriation of surface finish
6. BUE formation due to friction
7. Various zones of BUE
8. Weldment zone and its layer
9. Photo micro graph of partially formed chip produced by SWC tool
10. Transition of BUE to flow zone increasing cutting speed
11. Charecterisc graph of cutting force vs depth of cut under different rake angle
12. Ch. Graph of temperature vs different feed
13. BUE and Microchiping
14. Microscopic view of BUE
15. Tool wear and BUE formation
16. Variation of peak to valley roughness with cutting speed
17. Ch. Graph of cutting speed vs feed
18. BUE location at tool tip
List of Tables:-
1. Table-1(Characteristic graph of vs. Vc of Coated carbide tool in dry condition)
2. Table-2(Characteristic graph of vs. Vc of Coated carbide tool in Flood condition)
3. Table-3(Characteristic graph of vs. Vc of Un-Coated carbide tool in Flood condition)
4. Table-4(Characteristic graph of vs. Vc of Un-Coated carbide tool in dry condition)
Formation of Built-Up Edge, Its control & Prevention Page 7

Chapter-1
Theoretical Concepts of Built-Up Edge

Formation On various Machining Conditions
and on various Tool-Job Operations

Abstract :- A well-known phenomenon, the "built-up edge BUE", occurs at the

chip/tool interface when multiphase materials are machined at low cutting speeds.
Under high compressive stresses, seizure prevents the material from sliding over
the tool rake face. Although many reports have been published on the subject,
studies of the BUE phenomenon have been marked by a lack of precision in
determining its dimensions. The presence or absence of a built-up edge (BUE) is
important in relation to tool wear and surface finish. The possible mechanisms and
processes of wear influenced
by the different types of the
built-up edge are discussed.
Metallographic investigations
have shown that
recrystallization occurs in the
flowed layer. The flow of
submicroscopic crystallites
over the tool face influences
Fig.1 Formation of Built-Up Edge
tool wear. From the
investigation, the most favorable cutting conditions, from the point of view of both
wear and surface finish, occur in the absence of a built-up edge. This paper reports
on a study of the BUE geometry of a C20 steel machined at low speeds with and
without a cutting fluid.
The microstructure of the built-up edges of a number of alloys has been examined
using both optical and electron microscopy. The built-up edges of the two ferrific
steels examined showed that these were significantly different to those formed in
austenitic stainless steel. The built-up edge deformation system has been described
using three zones: primary shear (1), deformation around the build-up (2), and
deformation to form the build-up (3). The ferrific steels exhibited high-strain
deformation structures in both zones 2 and 3 with structures similar to those seen in
wire drawing and swaging. The stainless steel and Cu40Zn brass, however,
showed equi-axed grains about 02m in size with little or no twinning in zone 3.
Zone 2 of these materials showed considerable twinning and the resulting surfaces
were markedly less torn than those of the ferritic steels.

Introduction
When multiphase materials are machined at low cutting speeds, a phenomenon is
known as the "built-up edge BUE" may occur at the chip/tool interface. There is
evidence that the BUE occurs continuously along the material of the workpiece and
the chip, rather than constituting a separate body of hardened material over which
the chip slides (Trent, 1963).
Under high compressive stresses, the bonds are sufficiently strong to prevent the
material from sliding over the tool rake face. The chip is formed and moves by
plastic strain and it explains as follows: "... the first layer of the material connects to
the tool through atomic bonds and work hardens, thus increasing its yield point,
Successive layers from the BUE by the repetition of this process". It showed that the
BUE increases to a point at which the shear stress suffices to move the primary
shear zone (until then above the BUE) into the body of the BUE, where its structure
is sheared into parts that are dragged between the surface of the workpiece and the
tool clearance, and also between the chips lower surface and the tool rake face.
Figure 2 schematically depicts the process of BUE growth and the sharing of parts
of it, which is a cyclic process.
Fig:2 Scheme of BUE growth and shearing of parts

What is Built Up Edge ?
As the cutting speed is increased, the

friction between chip and tool will
increase;and when this becomes large
enough to cause a shear fracture in
the vicinity of the tool face, a built-up
edge (BUE) will form. There is no BUE
at very low cutting speeds since the
temperature on the face of the chip is
then not sufficient to cause the chip
surface to behave in a ductile manner.
With an increase in cutting speed, the
chip metal in contact with thechip face
becomes ductile, and the resulting Fig:3 Location Of BUE formation
plastic flow causes strong welds to form between chip and tool. The additional plastic
flow on the chip face causes strain-hardening and a further increase in the force
tending to anchor the chip to the tool. When the bonding force between chip and tool
exceeds the shear strength of the metal in the main body of the chip, at some
particularly weak point near the tool face, the BUE forms.
Moreover, the built-up edge is an accumulation of heavily strained work material,

which collects on the cutting edge under proper conditions. It is an undesirable feature
for several reasons. It reduces machining accuracy by changing the effective feed
rate. It also reduces the quality of the machined surface because it periodically breaks
off and reforms, introducing irregularities into the surface.The periodic breakage can
also lead to chipping of the cutting edge. Finally, built-up edge may also promote the
thermal cracking of the tool.
Built-up edge formation usually occurs at low cutting speeds. These speeds were
much more typical of industrial practice in the middle of the last century, and much of
the literature on the formation and avoidance of the built-up edge dates from this
period. (Built-up edge formation is still a problem in low-speed processes such as
drilling and end milling, especially for soft, ductile work material such as aluminum

alloys, and in minimum quantity lubrication machining.) The early work, much of which
concentrated on steel work materials, has been reviewed in detail by Ernst and
Martellotti [243] and Heginbotham and Gogia. Nakayama has more recently clarified
the relation of the built-up edge to cutting forces, temperatures, and surface finish. A
number of researchers have described built-up edge formation for work materials
other than steel and Trent has published a detailed discussion of the metallurgical
aspects of the phenomenon.
Built-up edge formation is similar

to discontinuous chip formation
in that it is a time-varying
process, which depends heavily
on toolchip friction and the
ductility of the work material. In
fact, the built-up edge can be
viewed as a partially formed
discontinuous chip around which
the undeformed work material
flows. The time-varying aspect
of the phenomenon and the
importance of toolchip friction
were demonstrated by
Fig.4: Growth of BUE (Embryo Formation)
Heginbotham and Gogias quick-
stop experimental studies using steel workpieces . They noted that the built-up edge
starts as an embryonic structure to which successive layers adhere as cutting
progresses, until it eventually attains a size and shape characteristic of the cutting
conditions. The size and shape may vary considerably;
Heginbotham and Gogia identified four distinct types of built-up edge for steel
workpieces that occur over specific speed ranges. Ultimately, the built-up edge breaks
off and the process of formation repeats itself.
Physically, the built-up edge comprises heavily strained and hardened material. Trent
reports that the micro-hardness of the built-up edge can be more than twice that of the
surrounding chip and that the strains involved in its formation are so high that they
cannot be estimated because the grain structure of the material is no longer
discernible. This observation further underscores the importance of the ductility of the
work material in built-up edge formation, since less ductile work materials will fracture

before such a structure can evolve. As noted earlier, the built-up edge increases the
effective rake angle of the tool and reduces cutting forces. A number of slip-line
solutions have been published for cutting with a built-up edge; these are similar to
those for conventional continuous chip formation, except that they include a roughly
triangular region of dead material at the tool point that does not deform.
Built-up edge formation has also been simulated using finite element models
since the built-up edge is an undesirable feature, however, it is probably of greater
interest to determine how it may be avoided. The standard method of reducing or
eliminating built-up edge formation is to increase the cutting speed, which increases
the toolchip interface temperature and reduces the strength of the work material near
the cutting edge. Other effective methods include applying a lubricant or tool coating
to reduce toolchip friction, increasing the rake angle to reduce stresses at the tool
point, and making the work material less ductile through cold work.
Fig.5: Gradual Chip Removal and detoriation of surface finish due formation of BUE

TOOLCHIP FRICTION AND SECONDARY DEFORMATION
Friction between the tool and the chip in metal cutting influences primary
deformation, built-up edge formation, cutting temperatures, and tool wear. An
understanding of toolchip friction is also necessary to develop accurate models for
cutting forces and temperatures, since frictional stresses and heat fluxes are often
used as boundary conditions .
The simplest way to characterize toolchip friction is to define an effective friction

coefficient, e, as the ratio of the cutting force P parallel to the tool rake face to the
force normal to the rake face, N:
e is sometimes converted to a friction angle , given by
= arctan (e)
N and P can be estimated from cutting force measurements as discussed in earlier.

e in cutting is usually larger than friction
coefficients measured in conventional sliding
friction tests; values above 1.0 are not
uncommon. Increased friction in cutting
results in part because the surface of the chip
is newly formed and thus atomically clean. e
usually increases with the rake angle and also
varies with the cutting speed. The friction
coefficient often reaches a maximum over a
narrow range of cutting speeds; in this range,
the chip adheres strongly to the tool and may
form a built-up edge.
Fig 6: BUE formation due to friction

Formation of the chip :- Machining is a process of gradual removal of

excess material from the performed blanks of the chips. The form of machining
chips is depending mainly upon
Work material
Material and geometry of the cutting tool
Levels of cutting velocity and feed and also depth of cut
Temperature and friction at the chip tool interfaces
Cutting fluid- flow ,type, velocity
Knowledge of basic mechanism(s) of chip formation helps to understand the

characteristics of chips and to attain favorable chip forms.
Mechanism of chip formation in machining ductile materials:-
During continuous machining the uncut layer of the work material just ahead of
the cutting tool is subjected to compression
Due to such compression shear stress developed
If the shear stress reaches or exceeds the shear strength of that work material in
the deformation region , yielding takes place resulting shear deformation at that
region.
Continuous chips are formed in machining ductile material such as mild steel ,
wrought iron, copper, and aluminum. Basically, this operation is one of sharing the
work material to form the chip and sliding of the chip along the face of the cutting
tool. The formation of chip takes place in a zone extending from the tool cutting
edge to the junction between the surfaces of the chip and workpiece: This zone is
known as primary deformation zone. To deform the material in this manner the
forces must be transmitted to chip across the interface between the chip and tool
are sufficient to deform the lower layers of the chip as it slides along the tool face
(secondary deformation zone).

Mechanism of Built-Up Edge (BUE):-

In machining ductile metals like steels with long chip-tool contact length, lot of
stress and temperature develops in the secondary deformation zone at the chip-tool
interface. Under such high stress and temperature in between two clean surfaces of
metals, strong bonding may locally take place due to adhesion similar to welding.
The presence of this welded material increases the friction and temperature
between chip and tool interface and leads to the building of layer upon layer of chip
material. This resulting pile of material is referred to as a built-up edge. (BUE).
Often the built-up edge continues to grow and then breaks down when it becomes
unstable, the broken
pieces being carried
away by the underside of
the chip an new
workpiece surface. A
study of built-up edge
formation in metal cutting
is most important as it is
one of the main factor
affecting surface finish
and can have a
considerable influence on
cutting tool wear.
Fig. 7: Various Zones of BUE
The method of adhering or welding of microchips or powdered particles present

during machining to the rake face of the cutting tool is called built up edge (BUE).
During machining operation always there is some amount of micro chips or
powdered particles will be produced. Also during machining according to the first
law of thermodynamics whatever the energy supplied will be converted into the heat
energy and due to this the rake face of the single point cutting tool is experiencing
high temperature. When the microchips or powdered particles are moving the rake
face of the tool, they will get exposed to high temperature environment and some of

the particles may get adhered or welded to the rake face of the tool called as built
up edge.
The BUE is a dynamic body that has a layered structure. When a point of particularly
high stress concentration approaches the outer face of the BUE, a new shear surface
forms and the BUE grows in size. The origin of the layered structure and the gradual
growth of the BUE due to a statistical array of imperfections in the work material is
shown figure. As the BUE grows forward, it will usually also grow downward, causing
the finished surface to be undercut. The BUE causes an increase in the rake angle
which in turn causes a decrease in the magnitude of the resultant force on the tool and
a clockwise rotation of the resultant force vector. For a small BUE the direction of the
resultant force is such asto put the BUE into compression and to make it stable. When
the BUE becomes large, the resultant force loads the BUE as a cantilever, and
eventually the moment at the base of the BUE becomes sufficient to pry it loose. The
BUE then passes off partly with the chip and partly on the finished surface.
Fig. 8 The built-up edge , a) Welds required to achor BUE to tool face. b) Origin layered
structure and growth and decay of BUE. c) Magnitude and direction of resultant force (R) for
small BUE. d) Magnitude and direction of cutting force.

Using the Built-Up Edge
Sorin (1955) demonstrated that unhardened steel in the shape of a tool was capable
of producing chips in a turning operation. While tool life was short, the soft tool was
definitely capable of producing chips. This suggests that a built-up edge (BUE) could
be utilized in cutting with reduced tool wear if the BUE is continuously replaced.
K. Hoshi (1939) extensively studied the characteristics of the BUE and, in the mid-
fifties, invented what he called the silver white chip (SWC) cutting technique as
reported by Hitomi (1961) and T. Hoshi (1980). The SWC technique involves tool
geometry that produces a BUE that is
caused to flow away continuously in the
form of a separate secondary chip. The
BUE is stabilized by chamfering the cutting
edge and the contact length is controlled by
a chip curler. The metal trapped by the
chamfer acts as the cutting edge and is
continuously replaced as the secondary
chip flows in a direction approximately
parallel to the principal cutting edge. It is a
photomicrograph of a partially formed chip
that shows the BUE trapped by the
chamfer. Figure shows the geometry of
SWC tools designed to cut low-carbon Fig. 9 Photomicrograph of partially formed chip
steel and gives recommended tool dimensionsproduced by SWC tool.
for different feed rates in mm/rev. The
SWC tool is reported to give 15% lower specific energy and about 20% longer tool
life than conventional tools. The lower cutting forces result in lower temperatures in
the primary chip that often do not give a temper color but a shiny silver surface,
hence the name silver white chip.
The SWC technique has been found to be most useful in Japan in rough-turning and
planning operations at high feed rates and low to moderate cutting speeds (Vc 100 m
min1). A relatively high feed rate is important since the extent of the chamfer should
be a fraction of the undeformed chip thickness.

A relatively large percentage of the cutting energy is convected away by a secondary

chip and, at high cutting speeds, this may be red hot. This then causes a softening of
the cutting edge and loss of tool geometry in the case of tungsten carbide. More
refractory ceramic or cermet tools should be better in this regard. The cutting speed
of SWC cutting is limited primarily by the temperature of the secondary chip and its
influence on the temperature of the tool tip.
The factors which influencing the formation of built up edge

are:
1.Speed of the machining: During machining with high speed, the time
available for adhering microchips will be less and formation of built up edge can
be neglected.
Cutting velocity Vc for given diameter D of a workpiece in turning or cutting tool(in

drilling, milling etc,) is varied by changing the spindle speed N as,

Vc =
1000
Too much increase in the speed N

leads to early failure of critical paths
like bearings of the machine tools,
severe vibration if there are eccentric
masses and even failure of some
elastic components of the machine
fixture tool work system by resonance
or near resonance.
Cutting force requirement: The major
cutting force component , Pz is
governed by several factors, as
Pz= ts0 f Fig.10 Transition of BUE to flow zone increasing cutting

speed

Where ts0 is the chip load (cross section of the chip before cut), is the shear
strength of the work material under the cutting condition and f is the form factor,
depending upon the sharpness of the cutting edge and friction between the chip and
tool. Equation shows that Pz is directly proportional to the values of feed S0 and
depth of cut t. therefore, too much increase in S0 and t for higher MRR may raise
Pz beyond the limit with respect to power consumption, dimensional deviation and
vibration.
2. Uncut chip thickness: As the uncut chip thickness increases, the force
induced during machining will increases which will increases the power
consumption and heat generation in machining process, hence the chances of
adhering microchips will be increased.
Mathematically, we can say,
c=(Vc X a1)
3. Back rake angle: Reduction in back rake angle will increases the forces in
machining and heat generation and hence the chances of formation of BUE will
increases.
We can say
mathematically,

= = ( )
If reduced then
must be increased and
power and heat
generation higher.
As, Power ,
Pz= ts0 f Fig.11 Characteristic graph of cutting force vs depth of cut under
different rake angle

The form factor is given by, f = - tan + 1, for ductile jobs,
f = 2( - tan ) for brittle jobs
4. Use of cutting fluids: During machining operation, if the cutting fluids are
used, whatever the heat generated during machining will be carried away by
the cutting fluid so that the heat available for adhering will be less and the
formation of BUE will be eliminated.
Also we can say that,

From the previous equation, = 21 = (2 ) , it is seen that, if the value of
friction factor decreases, then the value of chip reduction co-efficient also
decreases,
which in
turn
decrease in
cutting
force. So,
by
employing
proper
lubricant
for the
proper tool-
work
combinatio
Fig 12 Charecteristic graph of Temperature vs different feed
n we can control the formation of built-up edge.

Analysis of the evolution of the Built-Up Edge and Built-Up

Layer formation mechanisms in the dry turning
Tool wear is one of the main

parameters employed for evaluating
tool life, due to its influence in the loss
of quality of the manufactured parts.
So, minimising tool wear is possible to
maximise tool life and to optimise the
manufacturing performance. Different
mechanisms can cause the tool wear in
a specific machining process. Adhesion
wear is one of the tool wear
mechanisms that can be present in a
wider range of cutting temperatures. Fig 13 BUE and Microchiping
This type of tool wear can be produced by two different ways. On the one hand, direct
adhesion wear is caused by the incorporation of tool particles to the chips. On the other
hand, secondary adhesion wear is caused by the incorporation of fragment of the
workpiece material to the tool. This affects to
the tool wear in two ways. First, tool geometry
changes by the material incorporation. In a
second place, when these fragments are
removed, they can drag out tool particles
causing tool wear. Indirect adhesion can be
located in the tool edge, giving rise to the Built-
Up Edge (BUE) and/or in the tool rake face
giving rise to the Built-Up Layer (BUL). BUL
and BUE formation and their evolutions affects
to the workpiece quality. In this paper a study
Fig.14 Microscopic view of BUE of the BUL and BUE formation mechanisms,
their evolution and their influence on the dry
turned aeronautical workpieces surface quality has been achieved. In particular, this

study has been developed using aerospace aluminium alloys such as UNS A92024
(AlCu) and UNS A97050 (AlZn). Results have shown that BUE is formed by
mechanical adhesion mechanism. On the other hand, BUL is initially formed by thermo-
mechanical causes. However, a secondary BUL has been detected as a consequence
of the extrusion process of the BUE. Changes in BUL and BUE have been related with
the changes observed in the roughness profile of the machined pieces and evaluated
through the average surface roughness, Ra. So, a first relationship between the
adhesion effects and the surface finish of the worked samples has been found.
Obtained results have confirmed that BUE changes the tool position angle giving rise to
a reduction of Ra.
Effects of BUE:-
Built Up Edge (BUE) is the accumulation of workpiece material onto the rake face of
the tool. This material welds under pressure, and is separate from the chip.
Because BUE changes the effective geometry of the tool, it can have either
positive or negative effects.
Positive effects
Less tool wear
Lower power requirements
Less contact of the workpiece with the tool (It contacts the BUE instead)
Better surface finish and improved process capability
These effects
are only
beneficial if the
BUE is thin and
stable.
Machining
additives such as
sulfur combine
with manganese
to form
manganese
sulfides. Fig.15 a) Flank and crater wear in a cutting tool moves to the left. b) View of the rake of a
turning tool showing nose radius R crater wear pattern on rake face of the tool c) View of the
Manganese
flank face of a turning tool.

sulfide helps to control BUE because of its anti weld properties. On resulfurized steels,
BUE is usually stable and not a problem.
Negative effects
Poor tool life
Poor and variable surface finish ( As the BUE sloughs off the tool, it can weld to
the workpiece)
Loss of statistical capability on dimensional control
Loss of uptime trying to troubleshoot the process
I have found that BUE is more likely on alloys that work harden.
Fig.16 Variation of peak to valley roughness (Rt) with

cutting speed (V)
Fig.17 Characteristic graph of cutting speed vs feed

Necessary condition for showing built-up edge:-
The cutting speed is low. This is because at high cutting speeds the metal
moving away from the workpiece becomes hot enough to recover before seizing
onto the tool, preventing the formation of a BUE.
The metal being cut is one that work-hardens and is reluctant to recover (in the
stress-recovery sense).A BUE will not form with pure metals since they do not
work-harden much. Conversely, alloys, such as steel, do work-harden and recover
less so they are prone to forming a BUE.
Fig.18 Built-up Edge location at the tool tip

How to reduce built-up edge?
In general, built-up edge can be reduced by:
Increasing cutting speed.
Decreasing feed rate.
Increasing ambient workpiece temperature.
Increasing rake angle.
Reducing friction (by applying cutting fluid)
In order to get BUE under control, the steps that we take depend on the tool
material:-
For Carbide
Decrease the feed. (Pressure welding usually is the culprit)

Increase the speed
Increase the rake angle or hook
Get a better metalworking fluid
Get a different coating
For High Speed Steel (HSS)
Reduce speed
If the tool is High Speed Steel (HSS) you may think you are in opposite land when
you discover that slowing down the speed reduces the build up. I have found on
HSS that as speed (heat increases) so does the tendency to form BUE.

Conclusion:-
Built-up edge is formed as a result of the occurrence of the leading surface shear
stress, which under certain conditions at high pressure adhere the workpiece to the
edge. This material is harder than 80% and takes over the role of the cutting edge.
Build-up and its growth picking creating very obvious on the surface of the
machined surface abrasive increasing scales.
Steady accretion may improve the stability of the edge lifetime up to 5 times but the
most frequently due to the strong adhesive connections damage the blade.
Groove formation is associated with the curing of surface cutting is not associated
with the built-up edge.

Chapter-2
Experimental observation on Formation of Built Up Edge on

Various Jobs (C 30) and Various Tools (HSS, Coated & Un-Coated
Carbide) on various machining Conditions (Dry and Wet)

Project Outline
Objective:-
To experimental study on-
o The role of variation of the different machining parameters, cutting environment on tools and
patterns, type, size and the bond strength of the Built -Up Edge being formed in turning C20 steel
rods.
o Optimize the parametric combination for minimizing Built-Up Edge formation.
Literature review:-
o Location and pattern of Built-Up Edge formation

o Phenomenon and causes of Built-Up Edge formation
o Effects of Built-Up Edge formation
o Role of variation of different machining parameters on Built-Up Edge format on
o Control of Built-Up Edge formation
Material Used:-
o Jobs- C30 (100 X 600) ,

o Cutting Tools- a) HSS (0 10 8 8 20 60 0)
b) Uncoated carbide insert [P30/S4, SNUN 12 04 08]
c) Coated carbide insert [ SNUN 12 04 08] ( coated with TiAl, CNMG)
o Cutting Fluids- Soluble oil
Equipments to be needed and its purpose of use:-
A. Machine Tools: HMT Lathe

B. Slide caliper/micrometer: measuring chip reduction co-efficient
C. Microscope and camera: structure of Built-up Edge formation
D. Tally surf: measuring surface roughness
E. Dynamometer with DAS & PC: measuring cutting forces

Material: C30 Tool: Coated Carbide Condition: Dry
S0 S1 = .08 S2=0.1 S3=0.12 S4= 0.16
Vc
a2=0.72 a2=0.62 a2=0.50 a2=0.48
a1=0.077 a1=0.096 a1=0.115 a1=0.154
=9.35 =6.45 =4.34 =3.776
40
(m/min)
N=148
(rpm)
a2=0.68 a2=0.48 a2=0.54 a2=0.50

a1=.077 a1=0.096 a1=0.115 a1=0.154
=8.832 =5.00 =4.695 =3.896
60
(m/min)
N=250
(rpm)
a2=0.32 a2=0.26 a2=0.20 a2=0.18

a1=.077 a1= 0.096 a1=0.115 a1=0.154
125 =4.15 =2.70 =1.73 =1.168
(m/min)
N=420
(rpm)
a2=0.22 a2=0.26 a2=0.269 a2=0.18

a1=.077 a1=0.096 a1=0.115 a1=0.154
150 =2.875 =2.70 =2.26 =1.948
(m/min)
N=550
(rpm)

PROJECT PART- II PAPER CODE- ME 882
Material: C30 Tool: Coated Carbide Condition: Dry
Characteristics graph of Chip reduction co-efficient () vs. Cutting velocity (Vc)
Table 1
Page | 31
Material: C30 Tool: Coated Carbide Condition: Flood
S0 0.08 0.1 0.12 0.16
Vc
a2=0.8 a2=0.44 a2=0.384 a2=0.38
a1=0.077 a1=0.096 a1=0.115 a1=0.154
40 =10.38 =4.58 =3.478 =2.467
(m/min)
N=148
(rpm)
a2=0.44 a2=0.42 a2=0.46 a2=0.40

a1=.077 a1=0.096 a1=0.115 a1=0.154
60 =5.714 =4.375 =4.043 =2.59
(m/min)
N=250
(rpm)
a2=0.30 a2=0.28 a2=0.28 a2=0.34

a1=.077 a1= 0.096 a1=0.115 a1=0.154
125 =3.896 =2.91 =2.43 =2.20
(m/min)
N=420
(rpm)
a2=0.20 a2=0.24 a2=0.20 a2=0.26

a1=.077 a1=0.096 a1=0.115 a1=0.154
=2.597 =2.50 =1.75 =1.68
150
(m/min)
N=550
(rpm)
Page | 32
Material: C30 Tool: Coated Carbide Condition: Flood
Table 2
Page | 33
Material: C30 Tool: Uncoated Carbide Condition: Flood
S0 0.08 0.1 0.12 0.16
VC
a2=0.52 a2=0.54 a2=0.40 a2=0.48
a1=0.077 a1=0.096 a1=0.115 a1=0.154
=6.75 =5.625 =3.47 =3.14
40
(m/min)
N=148
(rpm)
a2=0.4 a2=0.66 a2=0.42 a2=0.50

a1=.077 a1=0.096 a1=0.115 a1=0.154
=5.19 =6.875 =3.625 =3.246
50
(m/min)
N=192
(rpm)
a2=0.28 a2=0.50 a2=0.48 a2=0.18

a1=.077 a1= 0.096 a1=0.115 a1=0.154
60 =3.63 =5.208 =3.10 =1.168
(m/min)
N=250
(rpm)
a2=0.32 a2=0.34 a2=0.30 a2=0.18

a1=.077 a1=0.096 a1=0.115 a1=0.154
=4.155 =3.54 =2.60 =1.16
80
(m/min)
N=325
(rpm)
Page | 34
Material: C30 Tool: Uncoated Carbide Condition: Flood
Table 3
Page | 35
Material: C30 Tool: Uncoated Carbide Condition: Dry
S0 0.08 0.1 0.12 0.16
VC
a2=0.48 a2=0.38 a2=0.46 a2=0.56
a1=0.077 a1=0.096 a1=0.115 a1=0.154
=6.21 =3.93 =3.96 =3.62
40
(m/min)
N=148
(rpm)
a2=0.4 a2=0.34 a2=0.38 a2=0.46

a1=.077 a1=0.096 a1=0.115 a1=0.154
=5.17 =3.54 =3.27 =2.97
50
(m/min)
N=192
(rpm)
a2=0.20 a2=0.30 a2=0.34 a2=0.42

a1=.077 a1= 0.096 a1=0.115 a1=0.154
60 =2.597 =3.125 =2.96 =2.72
(m/min)
N=250
(rpm)
a2=0.56 a2=0.24 a2=0.26 a2=0.34

a1=.077 a1=0.096 a1=0.115 a1=0.154
=7.27 =2.5 =2.26 =2.20
80
(m/min)
N=325
(rpm)
Page | 36
Material: C30 Tool: Uncoated Carbide Condition: Dry
Table 4
Page | 37
MACHINING FORCE IN TURNING C30 STEEL, BY UNCOATED CARBIDE TOOL UNDER DRY
CONDITION
SL No. Vc Feed, S0 FORCE (N) Remarks
(m/min) (mm/rev)
Pz Px
0.08 200 162
0.1 660 155

01 40
0.12 770 201
0.16 900 308
0.08 580 143
0.1 670 343

02 50
0.12 550 351
0.16 880 249
0.08 600 163
0.1 740 190

03 60
0.12 843 224
0.16 970 250
0.08 560 134
0.1 620 148

04 80
0.12 700 164
0.16 910 198
Page | 38
MACHINING FORCE IN TURNING C30, STEEL BY UNCOATED CARBIDE TOOL UNDER WET
CONDITION
SL Vc Feed, S0 FORCE (N) Remarks

No.
(m/min) (mm/rev) Pz Px
0.08 460
0.1 650
01 40 0.12 710
0.16 890
0.08 548
0.1 590
02 50 0.12 700
0.16 890
0.08 640
0.1 560
03 60 0.12 700
0.16 900
0.08 510
0.1 590
04 80 0.12 690
0.16 860
Page | 39
MACHINING FORCE IN TURNING C30, STEEL BY COATED CARBIDE TOOL UNDER DRY
CONDITION
No.
(m/min) (mm/rev) Pz Px
0.08 393 81
0.1 575 120
01 40 0.12 676 125
0.16 832 174
0.08 465 138
0.1 562 143
02 50 0.12 637 141
0.16 787 173
0.08 462 182
0.1 568 160
03 60 0.12 637 201
0.16 775 190
0.08 652 159
0.1 541 177
04 80 0.12 619 180
0.16 731 200
Page | 40
MACHINING FORCE IN TURNING C30, STEEL BY COATED CARBIDE TOOL UNDER WET
CONDITION

No.
(m/min) (mm/rev)
Pz Px
0.08 483 177
0.1 676 177

01 40
0.12 746 182
0.16 942 245
0.08 540 126
0.1 583 120

02 50
0.12 732 134
0.16 935 202
0.08 637 163
0.1 577 113

03 60
0.12 523 208
0.16 887 209
0.08 373 129
0.1 648 160

04 80
0.12 443 160
0.16 923 199
Page | 41
Sample Graph, in case of coated carbide tool using C30 material, in dry condition,
The characteristics graph between Fz (Main Cutting Force) and Time is shown.
Characteristics graph between Principal cutting force (Fz) vs Time (t);

Force measurement graph
Page | 42

Experimental Study on BUE Formation

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Experimental Study on BUE Formation

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Experimental Study on role of tool-work materials and

machining condition on Built up edge formation

Project: Part-II (ME-882)

Submitted in partial fulfillment of the requirement for the degree

B.TECH in Mechanical Engineering 2013-2017

SK. ANISH AHAMED SOUMYAJIT DAS

Mechanical Engineering Department

G.T. Road, Adisaptagram, P.O : Aedconagar

Hooghly-712121, West Bengal

STATEMENT BY THE CANDIDATE

I am thankful to my guide Prof. A.B. Chattopadhyay whose personal enrollment in the

a1 Chip thickness before cut e effective clearance angle

t Required time rake angle

N r.p.m. c temperature (fundamental

Formation of Built-Up Edge, Its control & Prevention Page 7

Theoretical Concepts of Built-Up Edge

Formation of Built-Up Edge, Its control & Prevention Page 8

Abstract :- A well-known phenomenon, the "built-up edge BUE", occurs at the

Formation of Built-Up Edge, Its control & Prevention Page 9

Fig:2 Scheme of BUE growth and shearing of parts

Formation of Built-Up Edge, Its control & Prevention Page 10

What is Built Up Edge ?

As the cutting speed is increased, the

Moreover, the built-up edge is an accumulation of heavily strained work material,

Formation of Built-Up Edge, Its control & Prevention Page 11

Built-up edge formation is similar

Formation of Built-Up Edge, Its control & Prevention Page 12

Formation of Built-Up Edge, Its control & Prevention Page 13

TOOLCHIP FRICTION AND SECONDARY DEFORMATION

The simplest way to characterize toolchip friction is to define an effective friction

e is sometimes converted to a friction angle , given by

N and P can be estimated from cutting force measurements as discussed in earlier.

Formation of Built-Up Edge, Its control & Prevention Page 14

Formation of the chip :- Machining is a process of gradual removal of

Knowledge of basic mechanism(s) of chip formation helps to understand the

Mechanism of chip formation in machining ductile materials:-

Formation of Built-Up Edge, Its control & Prevention Page 15

Mechanism of Built-Up Edge (BUE):-

Fig. 7: Various Zones of BUE

The method of adhering or welding of microchips or powdered particles present

Formation of Built-Up Edge, Its control & Prevention Page 16

Formation of Built-Up Edge, Its control & Prevention Page 17

Using the Built-Up Edge

Formation of Built-Up Edge, Its control & Prevention Page 18

A relatively large percentage of the cutting energy is convected away by a secondary

The factors which influencing the formation of built up edge

Cutting velocity Vc for given diameter D of a workpiece in turning or cutting tool(in

Too much increase in the speed N

Pz= ts0 f Fig.10 Transition of BUE to flow zone increasing cutting

Formation of Built-Up Edge, Its control & Prevention Page 19

Mathematically, we can say,

Formation of Built-Up Edge, Its control & Prevention Page 20

The form factor is given by, f = - tan + 1, for ductile jobs,

f = 2( - tan ) for brittle jobs

Also we can say that,

Formation of Built-Up Edge, Its control & Prevention Page 21

Analysis of the evolution of the Built-Up Edge and Built-Up

Tool wear is one of the main

Formation of Built-Up Edge, Its control & Prevention Page 22

Formation of Built-Up Edge, Its control & Prevention Page 23

Fig.16 Variation of peak to valley roughness (Rt) with

Fig.17 Characteristic graph of cutting speed vs feed

Formation of Built-Up Edge, Its control & Prevention Page 24