Mfg Eng II Chapter 5

1/4/2024
Chapter Four
Chip Formation
Introduction
 Chip: is a removed/sheared material from parent
material that flows along with the cutting tool surface in the
form of small pieces during metal cutting by fracture.
 Hence, machining is a process of gradual removal of excess
material from the preformed blanks in the form of chips.
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Mechanism of chip formation in machining
 Machining is a semi-finishing or finishing process

essentially done to impart required or stipulated
dimensional and form accuracy and surface finish to
enable the product to:
 fulfill its basic functional requirements
 provide better or improved performance
 Improve service life.
Cont’d…
 The form of the chips is an important index of

machining because it directly or indirectly indicates :
 Nature and behavior of the work material
under machining condition
 Specific energy requirement (amount of energy
required to remove unit volume of work
material) in machining work
 Nature and degree of interaction at the chip-
tool interfaces.
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Factors influencing the chip formation
 Chip formation affects:

 Surface finish
 Cutting force
 Temperature
 Tool life and
 Dimensional tolerance

Ductile materials
 During continuous machining the uncut layer of the work
material just ahead of the cutting tool (edge) is subjected to
almost all sided compression as indicated in Fig.
 The force exerted by the tool on the chip arises out of the
normal force, N and frictional force, F
 Due to such compression, shear stress develops, within that
compressed region, in different magnitude, in different
directions and rapidly increases in magnitude.
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Cont’d…
 When the value of the shear stress reaches or exceeds the

shear strength of that work material in the deformation
region, yielding or slip takes place resulting shear deformation
in that region and the plane of maximum shear stress.
 The forces causing the shear stresses in the region of the chip
quickly diminishes and finally disappears while that region
moves along the tool rake surface towards and then goes
beyond the point of chip-tool engagement.
 This phenomenon repeats rapidly resulting in formation and

removal of chips in thin layer by layer.
Cont’d…
 This phenomenon has been explained in a simple way

by Piispannen using a card analogy as shown in
Fig(a). below:
Fig (a): Shifting of the postcards by partial sliding against each other
Fig (b): Chip formation by shearing
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Brittle materials
 The two basic mechanisms involved in chip formation are:
 Yielding – generally for ductile materials
 Brittle fracture – generally for brittle materials
 During machining;
 first a small crack develops at the tool tip as shown in Fig.
below due to wedging action of the cutting edge. At the
sharp crack-tip stress concentration takes place.
 In case of ductile materials, immediately yielding takes

place at the crack-tip and reduces the effect of stress
concentration and prevents its propagation as crack.
Cont’d…
 But in case of brittle materials, the initiated crack quickly
propagates, under stressing action, and total separation
takes place from the parent work piece through the
minimum resistance path.
 Machining of brittle material produces discontinuous chips
and mostly of irregular size and shape.
 The process of forming such chips is schematically shown in
Fig.: a, b, c, d and e.
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Types of Chips
 The chips obtained in machining processes are classified into
four categories:
1. Continuous chips
2. Continuous with build –up edge
3. Discontinuous (segmented) chips
4. Serrated chips
1. Continuous chips
 A continuous ribbon-type chip is produced during the cutting
of ductile materials such as low carbon steel, aluminum alloys,
copper and brass,
 The tool presses against the material which is deformed
plastically.
 Here, the material is subjected to both compression and
shear.
 Plastic zone ahead of the cutting tool edge is called primary
zone of deformation and the deformation on the rake face is
called secondary zone of deformation.
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Cont’d…
Continuous chip:
 It is formed at high rake angle,
 Good surface finish are generally produced,
 Continuous chips are not always desirable ,

particularly in automated machines,
 They get tangled around a tool and the operations

has to be stopped to clear away
 Remedy- use of chip breaker
Conditions which favors continuous types of chips
 Ductile work
 Fine feeds
 Sharp cutting tools
 Larger rake angle
 High cutting speed
 Proper coolant
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2. Continuous with 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.
 Due to high temperature and pressure existing, the chip may
stick to the rake face of the tool.
 BUE is formed when there is a chemical affinity between the
work piece and tool.
 The weldment starts forming as an embryo at the most
favorable location and thus gradually grows as schematically
shown in Fig. below.
Cont’d…
 This type of chip is common in softer nonferrous

metals and low carbon steels.
 Favorable growth conditions for BUE are such as:
 High strain hardening
 Low speed
 Large depth of cut
 Low rake angle
 High temperature
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Cont’d…
Effects of BUE chip formation:
 It unfavorably changes the rake angle at the tool tip
causing increase in cutting forces and power
consumption,
 BUE causes fluctuation in cutting forces and thus induces
vibration which is harmful for the tool, job and the
machine tool,
 Surface finish gets deteriorated,
 May reduce tool life by accelerating tool-wear at its rake
surface.
Cont’d…
BUE can be reduced by:
 Increasing cutting speed
 Decreasing the feed rate
 Increasing the rake angle
 Use a sharp tool
 Reducing friction by applying cutting fluids
 Use a cutting tool that has lower chemical affinity

for the workpiece material.
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3. Discontinuous chips
 Discontinuous chips are produced during machining of brittle
materials such as cast iron and brasses.
 There is crack formation in the deformation zone ahead of
cutting edge.
 The crack travels with further advancement of tool and results

in formation of small lumps of chip.
 The formed discontinuous chips consists of segments that
may be firmly or loosely attached to each other
Cont’d…
 Discontinuous chips usually form under the following

conditions:
 Brittle workpiece materials, because they do not have the
capacity to undergo the high shear strains involved in
cutting,
 Workpiece materials that contain hard inclusions and
impurities or have structures such as the graphite flakes
in gray cast iron,
 Very low or very high cutting speeds,
 Large depths of cut,
 Low rake angles,
 Lack of an effective cutting fluid,
 Low stiffness of the tool-holder or the machine tool, thus
allowing vibration and chatter to occur.
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Remedy for discontinuous chips
 Increase the rake angle
 Decrease the depth of cut
 Use medium cutting speed
 Use of cutting fluids to reduce friction.
4. Serrated/segmented chips
 The other names of serrated chips are segmented chips and non-
homogeneous chips. It is a combination of continuous and
discontinuous chip
 This chip has a saw tooth appearance due to an alternating large
zone of high shear strain followed by a small zone of low shear
strain.
 Due to this cyclic chip formation, it becomes semi-continuous.

 This type of chip formation occurs while machining the difficult-to-
machine materials (such as titanium alloys, nickel-based super-
alloys, and austenitic stainless steel) at high cutting velocities.
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1/4/2024

Mechanism of chip formation in machining

 Machining is a semi-finishing or finishing process

 fulfill its basic functional requirements

 provide better or improved performance

 Improve service life.

 The form of the chips is an important index of

Factors influencing the chip formation

 Chip formation affects:

Mechanism of chip formation in machining

 When the value of the shear stress reaches or exceeds the

 This phenomenon repeats rapidly resulting in formation and

 This phenomenon has been explained in a simple way

Fig (b): Chip formation by shearing

Mechanism of chip formation in machining

 In case of ductile materials, immediately yielding takes

 The chips obtained in machining processes are classified into

2. Continuous with build –up edge

3. Discontinuous (segmented) chips

 It is formed at high rake angle,

 Good surface finish are generally produced,

 Continuous chips are not always desirable ,

 They get tangled around a tool and the operations

 Remedy- use of chip breaker

Conditions which favors continuous types of chips

 Sharp cutting tools

 Larger rake angle

 High cutting speed

2. Continuous with built-up edge (BUE)

 This type of chip is common in softer nonferrous

 Favorable growth conditions for BUE are such as:

 High strain hardening

 Large depth of cut

 Low rake angle

 Increasing cutting speed

 Decreasing the feed rate

 Increasing the rake angle

 Use a sharp tool

 Reducing friction by applying cutting fluids

 Use a cutting tool that has lower chemical affinity

 The crack travels with further advancement of tool and results

 Discontinuous chips usually form under the following

Remedy for discontinuous chips

 Increase the rake angle

 Decrease the depth of cut

 Use medium cutting speed

 Use of cutting fluids to reduce friction.

 Due to this cyclic chip formation, it becomes semi-continuous.

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