IUBAT- International University

of Business Agriculture and

Technology
Lab report on
Study of different types of chip and
determination of chip reduction coefficient

Prepared for
Md. Abul Bashar
Course Instructor
MEC-238-Manufacturing process Lab

Prepared By
MD. Ismail Morshed
ID# 13307017
Program: BSME
Section: Day

Date of Submission
12th April, 2015
1

Experiment name:

Study of different types of

chip and
determination of
chip reduction coefficient

Objectives:
I.
II.

III.

To learn classify chips and identify the condition for different chip
forms.
To learn illustrate and assess geometrical characteristics of
ductile chips :
chip reduction coefficient & cutting ratio
shear angle and cutting strain
To describe with illustration the mechanism of chip formation in
machining.

Introduction:
Chip formation is part of the process of cutting materials by
mechanical means, using tools such as saws, lathes and milling
cutters. An understanding of the theory and engineering of this
formation is an important part of the development of such machines
and their cutting tools.
The formal study of chip formation was encouraged around World War
II and shortly afterwards, with increases in the use of faster and more
powerful cutting machines, particularly for metal cutting with the new
high speed steel cutters.

Different types of chips:

I.

Type I chips: Type I chips form when a material splits ahead of

the cutting edge, owing to some upwards wedge action of the
tool exceeding the tensile strength of the material, perpendicular
to the surface. They are thus particularly important in fibrous
materials, such as wood, where individual fibres are strong but
they may be levered apart relatively easily. Type I chips generally
form in cutting by tools with shallow cutting angles. Type I chips
may form long, continuous swarf, limited in size only by the
2

length of cut. This is the idealised chip formation for wood

shavings, particularly those produced by a well-tuned plane with
a finely adjusted mouth.

Type-I chip

II.

Type II chip:
Type II chips form when a shearing force is
produced by the wedge of the tool angle. The material fails along
a short angled plane, from the apex of the tool edge, diagonally
upwards and forwards to the surface. The material deforms along
this line, forming an upward curling chip. These chips generally
form from intermediate cutting angles. Type II chips may form in
ductile materials, such as metals. Type II chips may also form
long, continuous swarf.

Type-II Chip

III.

Type III chip: Type III chips form from a compression failure of
the material, ahead of a relatively obtuse cutting angle,
approaching 90. In some weak or non-ductile materials this may
form an acceptable chip, usually as a fine dust, but often it gives
rise instead to a random "snowplough" effect where the waste
material is bunched up ahead of the tool but not cleared
decisively away as a well-formed chip.This type of chip is formed
by routers. It is also formed by woodworking scrapers, although
when properly sharpened and used, these form such a thin Type
III chip that it instead appears as a well-formed Type II chip. Their
waste chip is thin enough that the compression failure volume is
small enough to act as for the well-defined shear plane of the
Type II.

Type III chip formation during climb milling

IV.

Type 0 chip: This type was characterized later, by William

McKenzie (1960)

Mechanics of chip formation:

In general, machining is 3D-process. For providing an understanding

of mechanics of machining, we simplify the process into a 2D-process
called as Orthogonal Cutting as shown in above fig. In orthogonal
cutting, the work piece is a flat plate (it can be a thin tube too) and is
machined using a wedge-shaped tool with a rake angle of a and
a relief angle of q . The work piece is moving at a cutting speed of V
with a depth of cut to. The width remains unaffected. The chip
formation is a localized shear process in a narrow region where the
metal is compressed and then made to flow on the face of the tool.
The shear angle, f , is of fundamental importance. A smaller angle
implies a large shear plane leading to requirement of high cutting
forces. Let us develop some equations that help us understand the
process better.
1. Cutting ratio, r

If the chip thickness is tc, then we can show that

r = to/tc = Sin /Cos ( - )
r is always less than unity. Rearranging the equation gives,
tan = r Cos /(1-r Sin )
2. Shear Strain

Consider a square element subjected to a shear stress. If the

distance sheared is "a" and the edge length of square is "b", then
the shear strain is given by: = a/b.
In metal cutting, the shearing process is similar to a deck of
playing cards sliding against each other as shown in figure. See
Figure 8.3. We can write:
= AB/OC = (AO + OB)/OC = Cot + tan ( - )
Low shear and rake angles result in high . A value of >5
indicates much greater deformation in machining than in metal
forming where it is under 1.
3. Velocity Ratio

If the velocities are considered, we can write

Q = w toV = w tc Vc
V/Cos ( - ) = Vs / Cos = Vc/Sin
4. Shear Strain-rate

d /dt = Vs/d where d = OC ~ 10-3 to 10-4 inch

Shear strain rate is on the order of 103- 106/sec

Thus, it is this combination of large strains and high strain rates make
it difficult to predict chip formation.

Conclusion:
We learned a lot from this report concerning about chip formation. Its
an important term of machining for cutting process of manufacturing
process. Hopefully this will help us in our future mechanical career.

References:
http://en.wikipedia.org/wiki/Chip_formation
https://prezi.com/tn5dwdstzvtw/chip-reduction-coefficientduring-single-point-turning/
http://www.public.iastate.edu/~mebbs/courses/ME322/Machining
.html
MEC-237 class notes

******************
7