Experiment No: 01
STUDY OF CHIPS AND DETERMINATION OF CHIP REDUCTION CO-
EFFICIENT IN TURNING MEDIUM CARBON STEEL BY COATED
CARBIDE INSERT.
Objectives:
i. To study different types of chip (type, shape and color)
ii. To determine chip reduction co-efficient (ξ)
Theory:
Chip Formation:
When force is applied by cutting tool against the workpiece, the uncut layer deforms
first elastically followed by plastic deformation due to the shearing action near the
cutting edge of the tool. Shearing takes place along a shear zone and shear is of
maximum at the shear plane. After passing out of the shear plane, the deformed
material slides along the tool face as chip as cutting progresses.
ee
Fig.1.1: Schematic Representation of Chip Formation
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Four main categories of chips (as shown in Fig. 2) are:
Discontinuous chips:
These chips are small segments, which adhere loosely to each other. They are formed
when the amount of deformation to which chips undergo is limited by repeated
fracturing. Hard and brittle materials like bronze, brass and cast iron will produce
such chips.
Continuous or ‘ribbon’ chips:
In continuous chip formation, the pressure of the work piece builds until the material
fails by slip along the plane. The inside on the chip displays steps produced by the
intermittent slip, but the outside is very smooth. It has its elements bonded together
in the form of long coils and is formed by the continuous plastic deformation of
material without fracture ahead of the cutting edge of the tool and is followed by the
smooth flow of chip up the tool face.
Continuous chip with built up edge:
These types of chips are very similar to that of continuous type, with the difference
that it is not as smooth as the previous one. This type of chip is associated with poor
surface finish, but protects the cutting edge from wear due to movement of chips and
the action of heat causing the increase in tool life.
Serrated chips:
These chips are semi-continuous in the sense that they possess a saw-tooth
appearance that is produced by a cyclical chip formation of altering high shear strain
followed by low shear strain. This chip is most closely associated with certain
difficult-to-machine metals such as titanium alloys, nickel-based super-alloys and
aesthetic stainless steels when they are machined at higher cutting speeds. However,
the phenomenon is also found with more common work metals (e. g. steel), when
they are cut at high speeds.
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(a) Continuous chip (b)Discontinuous chip
(c) Continuous with built-up edge (d) Serrated chip
Fig.1.2: Four types of chip formation in metal cutting
Chip Shape:
Chip shape depends in the state of chip curling. Chip shape may be ribbon-like, helical
(tubular), spiral, one turn, half turn etc.
Chip
Shape
Group Half Turn Tubular/ Helical Spiral Ribbon-like
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Chip Color:
Chip color depends generally on the cutting conditions (cutting velocity, depth of
cut, feed rate etc). In dry cutting the chip color is generally blue or burned blue. In
wet conditions chip color generally in metallic, golden, or blue.
Chip Reduction Co-efficient:
Chip reduction co-efficient (ξ) is the ratio of chip thickness (a2) to uncut chip
thickness (a1), (as shown in Fig.1). Mathematically,
𝑎 𝑎
ξ = 𝑎12 =𝑠0 𝑆𝑖𝑛
2
∅
The inverse of ξ is known as cutting ratio, r c. ξ is an important index which indicates
the degree of deformation and hence the force required. ξ is affected by process
parameters (i.e. Vc, So, t, ᵧ etc) and other variables (i.e. friction at too-chip interface,
cutting fluid, tool material, work material etc).
Machine, Equipment and Work Material:
i. Lathe machine
ii. Work material (medium carbon steel)
iii. Cutting tool (coated carbide)
iv. Slide calipers
Procedure:
i. Turn the work material in an engine lathe with three different cutting velocities
(Vc) at a constant feed rate (So) and constant depth of cut.
ii. Repeat the above procedure for three different feed rates.
iii. Collect the chips obtained
iv. Study them to identify their types, shapes and colors.
v. Calculate the chips reduction coefficient for each chip.
vi. Plot the graphs ξ vs Vc, ξ vs So
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DATA SHEET
Study of chips in turning medium carbon steel by coated carbide insert
Work material :
Diameter :
Cutting tool :
Material :
Cutting conditions
Cutting velocity
: Feed rate :
Depth of cut :
Environment :
S0 N Vc a1 a2 ξ Chip
(mm/rev) (rpm) (m/min) (mm) (mm) type shape color
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Question/Answer:
1. What is the significance of ξ?
2. Will ξ be greater than 1 always? Why?
1. What is the difference in chips when r.p.m is high?
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