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Chip
Formation
Lecture Notes
Joyjeet Ghose
Email: joyjeetghose@gmail.com
Senior Lecturer,
Department of Production Engineering,
Birla Institute of Technology, Ranchi
Chip Formation
• Regardless of the tool being used or the metal being cut, the chip forming
process occurs by a mechanism called plastic deformation. This
deformation can be visualized as shearing. That is when a metal is
subjected to a load exceeding its elastic limit.
• This action, shown in Figure is similar to the action that takes place when
a deck of cards is given a push and sliding or shearing occurs between the
individual cards.
FIGURE : Various chips produced in turning: (a) tightly curled chip; (b) chip hits workpiece and breaks; (c)
continuous chip moving away from workpiece; and (d) chip hits tool shank and breaks off. Source: G.
Boothroyd, Fundamentals of Metal Machining and Machine Tools.
KM
FIGURE : Effect of workpiece microstructure on tool life in turning. Tool life is given in terms of the
time (in minutes) required to reach a flank wear land of a specified dimension. (a) ductile cast iron. (b)
Steels, with identical hardness. Note the rapid decrease in tool life as the cutting speed increases.
Source “ Manufacturing Processes for Engineering Materials”, 4th edition, Kalpakjian, Schmid,
Prentice Hall 2003
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Effect of Workpiece Microstructure on Tool Life in Turning
• The tool life curves above are obtained in cutting various ductile cast irons. Note
the rapid decrease in tool life as the cutting speed increases and the strong
influence of the condition of the work piece material microstructure on the tool
life.
• Effect of cutting speed upon material removal: a material is being machined in
the “a” condition – 265 HB; see the figure above
• if the cutting speed is 70 m/min, tool life is about 40 min and the tool has
“traveled” 70 m/min X 40 min = 2800 m before being replaced.
• if the cutting speed is increased to 120 m/min, tool life is about 5 min and the tool
“travels” 120 m/min X 5 min = 600m.
• the lower cutting speed allows more material removal per tool but the part cannot
be produced as quickly – this is an economic trade-off.
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Tool life
Tool life curves are usually plotted on log-log paper or are plotted taking log of the
equation, from which we can easily determine the exponent “n”.
FIGURE : (a) Tool-life curves for a variety of cutting-tool materials. The negative inverse of the
slope of these curves is the exponent n in tool-life equations. (b) Relationship between measured
temperature during cutting and tool life (flank wear). Note that high cutting temperatures
severely reduce tool life. Source: After H. Takeyama and Y. Murata
Cv
V= 1
Where, S= feed in mm/min T s y v t xv
m
t= depth of cut mm
FIGURE :Graphs showing (a) cost per piece and (b) time per piece in machining. Note the optimum
speeds for both cost and time. The range between the two optimum speeds is known as the high-
efficiency machining range
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Economics of machining
The two most important parameter in in economics of machining are
the minimum cost per part and the maximum production rate. The total
cost per piece consists of four items:
C p = C m + C s + Cl + Ct
Where Cp is cost per piece, is the machining cost, Cs is the cost of setting
up for the machine for particular operation, Cl is the cost of loading,
unloading, and machine handling, and Ct is the tooling cost, which
includes tool changing, regrinding, and depreciation of the cutter. The
machining cost is given by
Cm = Tm ( Lm + Bm )
Where Tm is the machining time per piece, Lm is the labor cost of the
operator per hour, Bm and is the burden rate, or overhead charge of the
machine including depreciation, indirect labor etc.
L πLD
Tm = =
fN fV
From Taylor’s tool life equation
1
C n
T =
V
∂C p
=0
∂V
T0 = 1 − 1
n
[( ) ] Tc ( Lm + Bm ) + Tg ( Lg + Bg ) + Dc
Lm + Bm