Indian Institute of Technology Delhi

Manufacturing Processes - II

Module – 2 : Mechanics of Machining

Lecture – 5 : Mechanism of chip formation

1
 Indian Institute of Technology Delhi

Instructional objectives :
To enable the students, at the end of this lecture,
(i) describe with illustration the mechanism of
chip formation in machining
• ductile materials and
• brittle materials
(ii) describe geom. characteristics of ductile chips
• chip reduction coefficient & cutting ratio
• shear angle and cutting strain
(iii) Identify the causes, characteristics and effects
of built – up – edge (BUE) formation.
(iv) Classify chips and identify the conditions.
2
 Indian Institute of Technology Delhi

Machining is characterised by gradual material

removal in the form of chips.

The form of chips is an important index of

machining as it indicates :

• nature and behavior of the work material

under machining
• specific energy requirement to machine
• nature and degree of interaction at the
work – tool interfaces.
3
 Indian Institute of Technology Delhi

The form and colour of chips depend upon

• work material
• cutting tool – material and geometry
• levels of the process parameters
• application of cutting fluid

4
Indian Institute of Technology Delhi
Mechanism of chip formation in machining
ductile materials
a1: chip thickness (before cut)
a2: chip thickness (after cut)

Vf
Work

F
Tool N
R
o
VC

5
 Indian Institute of Technology Delhi

Lamellar chip formation by shear

Piispanen’s model of card analogy to explain

Chip formation in ductile material
6
 Indian Institute of Technology Delhi
Experimental study of chip formation
Purpose :
Experimental methods :
• study of grid deformation
• study of frozen chips
• study of running chips by high speed camera

7
 Indian Institute of Technology Delhi
Chip formation in machining brittle materials

8
 Indian Institute of Technology Delhi

(ii) Geom. characteristics of continuous chips

• chip reduction coefficient () & cutting ratio (r)

9
 Indian Institute of Technology Delhi

Kronenberg’s model : relating  with  and 


 (  o )
 e 2

 10
 Indian Institute of Technology Delhi

VC'

• shear angle, o a1
Shear plane

A
B

o
a2

(o - o)

O o
C

AC = a2 = OAcos(o-o) VC
o
AB = a1 = OAsino

cos  o r cos  o
tan  o  
  sin  o 1 r sin  o
11
 Indian Institute of Technology Delhi

• Average cutting strain, 

s PM
 
Y ON
o
s
s

Y
O
M
o
N
P s shear strain
Y
o
PN  NM PN NM
  
ON ON ON
  cot  o  tan(  o o ) 12
 Indian Institute of Technology Delhi

(iii) Built – up – edge (BUE) formation

• Causes of BUE formation

13
 Indian Institute of Technology Delhi

• characteristics of BUE
Shape, size and bond strength of BUE depends on:
• work – tool materials
• tool geometry
• stress and temperature
• cutting fluid application

14
 Indian Institute of Technology Delhi

• Effects of BUE formation

— unfavourable rake angle and consequences

— fluctuation in cutting forces and consequences
— poor surface finish
— may reduce tool life

15
 Indian Institute of Technology Delhi
(iv)Types of chips & condns. favouring those chip forms
Type of chips conditions
Work Cutting Feed Rake CF
matl. Vel. VC so angle,
1.discont. type
• irregular absent/
size & shape Brittle
inadeq.
• regular Ductile medium large - ve
size & shape but hard
2. cont. type Duct.&soft high low + ve profuse
• without BUE
Duct. medium med. / absent/
• with BUE large inadeq
&sticky
3. Jointed type Semi low / med. / - ve abs./
ductile medium large inadeq.
16
 Indian Institute of Technology Delhi
A. Quiz test
Identify the correct one out of the four given answers
1. In turning mild steel the value of  will be
(a) > 1.0
(b) < 1.0
(c) = 1.0
(d) none of the above
2. The value of shear angle, o depends upon
(a) tool rake angle
(b) friction at chip-tool interface
(c) built – up – edge formation
(d) all of the above
(contd.) 17
 Indian Institute of Technology Delhi

3. Shaping grey cast iron block will produce

(a) continuous chip with BUE
(b) continuous chip without BUE
(c) discontinuous chip of irregular size & shape
(d) discontinuous chip of regular size & shape

4. The value of chip reduction coefficient,  does

not depend upon
(a) cutting velocity
(b) depth of cut
(c) cutting tool material
(d) tool rake angle
18
 Indian Institute of Technology Delhi

B. Numerical problem

1. During plain turning mild steel by a tool of

geometry, 0o, 00, 8o, 7o, 15o, 90o, 0 (mm) at
so= 0.2 mm/rev, the chip thickness was found to
be 0.5 mm. Determine the values of  and o
in the above case.

19
 Indian Institute of Technology Delhi
Answers
A. Quiz Test
1 – (a)
2 – (d)
3 – (c)
4 – (b)
B. Numerical Problem
a2 a2 0.5
     2.5
a1 so sin  0.2x sin 90o

cos  o cos 0o
tan  o   [   0 o
]
and   sin  o 2.5  sin 0 o o

1 1
   0 .4
 2 .5
  o  tan 1(0.4)  21.8o
20
Indian Institute of Technology Delhi

THANK YOU

21