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Metal ahead of the cutting tool is compressed. This results in the deformation or elongation of the crystal structureresulting in a shearing of the metal. As the process continues, the metal above the cutting edge is forced along the chip-tool interference zone and is moved away form the work.
GMP-20.271 Chiappone
GMP-20.271 Chiappone
Chip Formations
GMP-20.271 Chiappone
Discontinuous
Typically associated with brittle metals like Cast Iron As tool contacts work, some compression takes place As the chip starts up the chip-tool interference zone, increased stress occurs until the metal reaches a saturation point and fractures off the workpiece.
Rensselaer Polytechnic Institute
GMP-20.271 Chiappone
Discontinuous
Continuous
Continuous ribbon of metal that flows up the chip/tool zone. Usually considered the ideal condition for efficient cutting action.
GMP-20.271 Chiappone
Continuous
GMP-20.271 Chiappone
Same process as continuous, but as the metal begins to flow up the chip-tool zone, small particles of the metal begin to adhere or weld themselves to the edge of the cutting tool. As the particles continue to weld to the tool it effects the cutting action of the tool.
GMP-20.271 Chiappone
This type of chip is common in softer non-ferrous metals and low carbon steels. Problems
Welded edges break off and can become embedded in workpiece Decreases tool life Can result in poor surface finishes
GMP-20.271 Chiappone
In metal cutting the power input into the process in largely converted to heat. This elevates the temperature of the chips, workpiece, and tool. These elements along with the coolant act as heat sinks.
GMP-20.271 Chiappone
Coolants/Cutting fluids
GMP-20.271 Chiappone
Machining Operations
GMP-20.271 Chiappone
Inputs Work material Type of cut Part geometry and size lot size Machinability data Quality needed Past experience of the decision maker
Rensselaer Polytechnic Institute
GMP-20.271 Chiappone
Constraints
Manufacturing practice Machine condition Finish part requirements Workholding devices Required process time
GMP-20.271 Chiappone
Outputs
GMP-20.271 Chiappone
GMP-20.271 Chiappone
High hardness Resistance to abrasion and wear Strength to resist bulk deformation Adequate thermal properties Consistent tool life Correct geometry
GMP-20.271 Chiappone
Tool Materials
Wide variety of materials and compositions are available to choose from when selecting a cutting tool
GMP-20.271 Chiappone
Tool Materials
They include:
Tool steels - low end of scale. Used to make some drills, taps, reamers, etc. Low cost equals low tool life. High speed steel(HSS) - can withstand cutting temperatures up to 1100F. Have improved hardness and wear resistance, used to manufacture drills, reamers, single point tool bits, milling cutters, etc. HSS cutting tools can be purchased with additional coatings such as TiN which add additional protection against wear.
Rensselaer Polytechnic Institute
GMP-20.271 Chiappone
Tool Materials
Cobalt - one step above HSS, cutting speeds are generally 25% higher. Carbides - Most widely used cutting tool today. Cutting speeds are three to five times faster than HSS. Basic composition is tungsten carbide with a cobalt binder. Today a wide variety of chemical compositions are available to meet different applications. In addition to tool composition, coatings are added to tool materials to incerase resistance to wear.
GMP-20.271 Chiappone
Tool Materials
Ceramics - Contain pure aluminum oxide and can cut at two to three times faster than carbides. Ceramic tools have poor thermal and shock resistance and are not recommended for interrupted cuts. Caution should be taken when selecting these tools for cutting aluminum, titanium, or other materials that may react with aluminum oxide.
GMP-20.271 Chiappone
Tool Materials
Cubic Boron Nitride(CBN) - This tool material maintains its hardness and resistance to wear at elevated temperatures and has a low chemical reactivity to the chip/tool interface. Typically used to machine hard aerospace materials. Cutting speeds and metal removal rates are up to five times faster than carbide. Industrial Diamonds - diamonds are used to produce smooth surface finishes such as mirrored surfaces. Can also be used in hard turning operations to eliminate finish grinding processes. Diamond machining is performed at high speeds and generally fine feeds. Is used to machine a variety of metals.
Rensselaer Polytechnic Institute
GMP-20.271 Chiappone
Tool Geometry
GMP-20.271 Chiappone
Tool Geometry
GMP-20.271 Chiappone
Tool Geometry
GMP-20.271 Chiappone
Rake Angles
Back-Allows the tool to shear the work and form the chip. It can be positive or negative
Positive = reduced cutting forces, limited deflection of work, tool holder, and machine Negative = typically used to machine harder metalsheavy cuts
The side and back rake angle combine to from the true rake angle
GMP-20.271 Chiappone
Rake Angles
GMP-20.271 Chiappone
Rake Angles
Rake Angles
GMP-20.271 Chiappone
These materials tend to be much more brittle than HSS but they hold superior hardness at high temperatures. The negative rake angles transfer the cutting forces to the tool which help to provide added support to the cutting edge.
Rensselaer Polytechnic Institute
GMP-20.271 Chiappone
GMP-20.271 Chiappone
GMP-20.271 Chiappone
GMP-20.271 Chiappone
GMP-20.271 Chiappone
GMP-20.271 Chiappone