Interim Report

On
EXPERIMENTAL STUDY ON CHIP CONTROL WITH DIFFERENT RAKE ANGLE
AND INCLINATION ANGLE

Under esteemed guidance of Mr. N.Krishna Rao

Submitted by
ABINASH DASH
ENR NO: 071931080

PPN - 140

Department of Mechanical Engineering

School of Engineering and Technology

INDIRA GANDHI NATIONAL OPEN UNIVERSITY

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 SYNOPSIS

TITLE OF THE PROJECT - EXPERIMENTAL STUDY ON CHIP CONTROL WITH DIFFERENT

RAKE ANGLE AND INCLINATION ANGLE
OBJECTIVE OF THE STUDY-To determine the chip thickness, length of the chip, chip
radius according to the change of rake angle inclination angle with variable cutting speed.
Rational of the study Despite rapid growth in the application of metal machining in,
manufacturing a compressive analysis of the problem of chip control has always been a
difficult task .This is because of the complex mechanism of the chip formation process and a
lack of knowledge of the factors that influence chip form are chip breakability under a given
set of input machining conditions. Duo to the wrong tool geometry can occur some hazardous
cases to the work piece surface, the operator & the machine tools. Like the long chip curls
around the tool and damage both tool and machine. So chip control can be done by suitable
monitoring and adaptive control process and effective chip control which aids in the accuracies
of acceptable chip form which can be evacuated easily and reliably from the working zone.
DETAILED METHODOLOGY TO BE USED FOR CARRYING OUT THE STUDY
Orthogonal machining testes were carried out bon mild steel tubes using hss cutting tools
with 10% cobalt.
Chip breaking was accomplished using as step type chip breaker.
Chip thickness and chip curl radius were measured using and image analyser.
Chip curl radius before breaking was determined taking account the elastic recovery of
chip
A procedure of chip breaker design to a chip effective breaking is also suggested.
EXEPCTED CONTRIBUTION FROM THE STUDY-01

LIST OF ACTIVITES TO BE CARRIEDOUT:- Orthogonal cutting, chip collection

PLACE:-at work shop of arya iron and steel situated barbil, orissa
EQUIPMENTS: - MACHINE LATHE
TOOLS:-High speed cutting tool having 10% cobalt.

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METHODOLOGY OF THE STUDY

The main goal of this experiment study is to better understand how variations cutting
parameters affect the chip form. Based on the assumption presented in the introduction, the
following aspects of the chips were measured.

The different parameters of chip measurements were taken using an image analyser, tool
maker instrument, digital mocrometer.The precision of this machine was determine by
measuring 1mm on a ruler 20 times ; the standard deviation was 18.4 microns.

PROCEDURE

Curl type chip thickness was measured with the help of tool maker instrument .It is a two
dimensional instrument. It has two axes that is horizontal & vertical .Chip was kept at the base
plate of instrument chip was shifted at the centre of axes with the help of adjustable
microscope. This instrument contains two types of reading scales i.e. horizontal & vertical. The
inner & outer dia of chips were measured three to four times by these reading scales.

Step1:
Initial & final inner dia of the chips was measured with help of vertical scale reading
Step2:
Average of these two readings was taken.
Step3:
Thickness (t-1) was measured by the difference of these two reading.
Step4:
Again, initial & final inner dia of chips was measured with help of horizontal scale readings.
Step5:
Now, thickness (t-2) was measured by the difference of these two readings.
Step6:
The greater of thickness (t1, t2) was taken as the final readings.
Step7:
Step1, 2, 3, 4, 5, 6, were repeated for calculating the thickness of outer dia of chips.
Thickness & dia of spiral & helical chips were measured with help of image analyser and
digital micrometre.
For each individual experiment, there were multiple outputs.to rectify these into a single
measured output for each input, the result were averaged based on the number of each type of
chip. For example, if there were 8 chips of length A and 2 chips of length B, then the result of
that experiment would be chips of length [0.8(A) +0.2(B)].there was also the option to average
the results based on the weight of each chip type. For example, if all the chips of length A were
a combined weight of 3 grams, and all the chips of length B were a combined weight of 7
grams, the final length would be [0.3(A) +0.7(B)].however the data presented in this report
was not averaged by weight, but by number as discussed above this prevents one large chip
from greatly skewing the data of many small chips.

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STATEMENT OF THE PROBLEM

Despite rapid growth in the application of metal machining in manufacturing a comprehensive

analysis of the problem of chip control has always been a difficult task. This is because
complex of the chip mechanism of the chip mechanism process and a lack of knowledge of the
factor that influence chip from/chip breakability under a given set of input machining
conditions such as work material properties, tool geometry, chip breakers and cutting
conditions. Consequently the solution to the problem has been approached empirically with a
limited degree of success.

In the present investigation, an attempt has been made to examine chip breaking by a
steptype chip breaker using the rigid plastic slip-line field theory .Orthogonal machining is
assumed and the deformation mode is analysed using the solutions pro-posed earlier by Kudo
and Dewhurst. The rake face friction is represented by the adhesion friction law suggested by
Maekawa et al. The fields are constructed and analysed by the matrix operational procedure
developed by Dewhurst and Collins. limit of validity of the fields has been determined from
the consideration of the over stressing of the rigid vertices at the chip and the work piece and
also from the consideration that friction angle along the tool face nowhere becomes negative
.the extent of material damage is assessed by computing the cumulative shear strain suffered
by the material in passing through the primary shear line and secondary deformation zones, by
ma method due to Atkins et al. variation of total strain breaking strain and the chip curl radius
and the chip breaker height and its distance from the cutting edge is studied. The variation at
the chip thickness is estimated .the accuracy of prediction of the degree of chip breaking by
some of the breakability criterion is examined in the light of rigid perfectly plastic slip-line
field theory.

It is found that as the chip breaker moves away from the cutting edge the radius of chip
curvature (Rchip/t0),tool chip contact length (ln/t0),specific cutting energy (fc/t0),cutting ratio
and total strain t in the chip increase while the breaking strain and the secondary strain
decrease. This observation is found to be influenced both by uncut chip thickness t 0 and tool
rake angle . The cutting force increases as WTR increased and rake angle decreased,
however the reverse trend is exhibited by chip breaker force F b.The amount of shear strain in
the secondary deformation zone is found to be about 10 to 15 % of total strain. The trend of
variation of total strain ct, specific cutting energy (fc/t0)and the breaking strain b with chip
breaker position supports the view that chip breaking is governed mainly by the breaking strain
and not by material damage or by specific cutting energy consumed during machining.

It is seen that chip breakability criteria based on t0 chip and R chip predict the
effectiveness of chip breaking more accurately than those based on specific cutting energy and
material damage.

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INPUT/DATA/STRUCTURE/QUESTIONNARIE:-

Machining chip control has been overlooked in manufacturing process control for a long time.
However with the automation manufacturing process chip control becomes an essential issue
in machining operation in order to carry out the manufacturing process efficiently and
smoothly, especially in todays unnamed machining systems and finishing operations.

On the three main areas of chip control study include chip formation ,which covers chip flow
and curl and chip breaking many experiments have been conducted .however given the
complicated nature of chip formation, breaking and the progressive insert groove production
,the result from analysis do not match with industrial expectation. This chapter gives an
overview in two categories; chip formation and chip breaking.

OVERVIEW OF CHIP FORMATION

After material removed from the work piece, it flows out in the form of chips. After flowing
out, the chip curls either naturally or through contact with obstacles.
The most logical approach in developing cutting models, for machining with chip
breaking is first to investigate and understand the direction of chip flow, since chip curling and
the subsequent chip breaking process depend very heavily on the nature of chip flow and its
direction.

For chip flow study, the most important objective is to establish the model of the chip side flow
angle, which in most research is called the chip flow angle.figure1-1 shoe chip side-flow angle.

Figure 1-1 chip side flow Angle9stabler 1964)

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Naturally chip will curl after it flows out. Contact with the chip breaking groove or chip
breaker or other obstacles will also make chip curl. There are three basic forms of chip curl,
and combinations of these construct chip shapes:

Chip up curl

Chip side curl

Chip lateral curl that was found in recent studies

The chip curl study requires the modeling of the chip up curl and side curls radii, both of
which have significant influences on chip-breaking. Figure 1-2 shows chip up-curl and side-
curl.

Figure 1-2 chip side curl and chip up-curl (spaans1971)

OVER VIEW OF CHIP BREAKING

In machining chips that vary in shape and length, short broken chips are desired because:
Operators safety(in manual operation )
Safety of machine tools and cutting tools

Manufacturing good surface finish on the machined surface

Convenience of chip disposal

Reduction of cutting temperature

Increasing tool life end

Possible power reduction

Therefore the study of chip breaking is very important for optimizing the machining process.
This importance is more significant in ductile materials such as soft gummy low carbon, tough

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steel leaded or resulferlized steels and other soft materials and light cuts with positive rake
angle tools.
Efficient chip control will contribute to higher reliability of the machining process, a better
finished surface, and increased productivity.
Chip breaking for brittle and ductile materials happen in different ways. When brittle metal
such as cast iron and hard bronze are cut discontinuously segmented chips are produced
naturally. As the point of the cutting tool contacts the metal, some compression occurs, and the
chip begins flowing along the chip tool interface. As more stress is applied to the brittle metal
by cutting action, the metal compress until it reaches a point where rupture occurs and the chip
separates from the un machined portion. This cycle is repeated indefinitely during the cutting
operation, with the rupture of each segments occurring on the shear angle of plane. Generally
as a result of these successive ruptures, a poor surface is produced on the work piece .

FIGURE 1-3 CHIPS BREAKING IN BRITTLE MATERIALS

In each cycle of ductile materials chip breaking, a chip first flow out with some initial
curling. Then the chip will keep on flowing out until it comes into contact with
(simultaneously blocked by) obstacles like the work piece surface or the cutting tool. The chip
curl radios will then becomes larger and larger with the chip continuously flowing out. When
the chip curl is tight enough to make the chip deformation exceed the chip material breaking
strain, the old chips will form; grow out (see figure1-4).

CHI PBREAKING OF DUCTILE MATERIAL

Therefore the chip will break when the actual chip fracture strain () is smaller than the tensile
strain of the chip (B),

The chip breaking research includes many components and activities including:
Work piece material

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 Tool geometry(including chip breaker features)

Process parameters(built-up edges,vibration,force,heat,tool wear)

Cutting condition(federate,depthof cut,cutting speed)

Coolant

Figure 1-5 shows the main scope of chip-breaking study. Its goals are to: establish a
chip-breaking model for prediction, design machining process, select tool, and design tool.

Feed rate
depth of cut

Workplace Cutting
Material speed

Chip
Breaking Tool wear
BUE

Environmental Cutting
conditions INSERT fluid

Nose Chip Back wall Rake

radius groove
Angle

Figure 1-5 research fields of chip control (Zhou 2001)

To break chips by mechanical obstacles there are two main chip-breaking modes: chip
breaking by chip/work-surface contact and chip-breaking by chip/tool flank surface contact
(figure1-6).in the first mode a chip may break by contact with the surface to be machined,
which is caused by chip side curl(figure 1-6e).it can also, break by contact with the machined
surface(shoulder of work piece)caused by chip up curl(figure1-6a,1-6b),the second breaking

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mode chip breaks by contact with the flank-surface caused by both chip up (figure 1-6c)and
side curl(Figure 1-6d).

Figure 1-6 models of chip breaking (Nakayama 1960)

In this the chip breaking in up curl chips is studied, and later on this type of chip formation
and

breaking will be analyzed in detail.

There are three major factors that affect chip breaking:

Changing cutting condition (Feed rate, depth of cut, cutting speed)

Change cutting tool geometric features(nose radius, rake angle, lead angle)

Design and use a chip breaker or chip breaking groove(groove width,backwall height,
back wall angle)

Increasing the depth of cut or the feed rate can significantly improve chip breakability.
However in industries this is not practical in finish cutting due to the limitations of machining
process. Therefore, optimizing the design of the cutting tools geometric features and the chip
breaker/chip breaking groove is the most plausible and efficient way to break the chip.

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ANALYSIS/SOLUTION/DESCRIPTION
2.1 LITERATURE REVIEW OF CHIP FORMATION AND BREAKING

This chapter reviews both previous woks done by researchers on fundamentals of chips-
formation and breaking, and attempts to develop chip-breaking criteria. The NAkayamas chip-
breaking criterion and Lis work on chip-breaking limits are reviewed in detail, this is
particularly important because the chip breaking predictive models developed in this thesis are
based on chip-breaking limits theory and on Nakayamas work. Finally, exiting problems in
chip-control and formation models are also reviewed.

2.2 Chip flow

Chip breaking modes depend on the nature of chip flow and its direction .understanding the
chip flow mechanism is important for chip flow mechanism is important for chip-control .chip
flow is determined by many factors and is usually described by the chip flow angle ().the
chip flow angle is the angle between the chip flow direction on the cutting tool rake face and
the normal line of the cutting edge (see figure2.1). Establishing the model of the chip flow
angle is the main objective of chip flow research. Due to the extreme complexity of the chip
formation process, only limited success has been achieved in chip flow research, especially in
three dimensional conditions (three dimensional grooves, and three dimensional cutting).

A lot of work has been done on chip flow angle research during the last few decades, and there
are many methods for calculating the chip flow angle. The investigation of chip flow began
with modelling over plane rake face tools.

Figure 2.1 chip side Flow angle (jawahir,1993)

Merchant, Shaffer and lee used the plasticity theory to attempt to obtain a unique
relation between the chip shear plane angle, the tool rake angle and the friction angle between
the chip and the tool (merchant, 1945: lee 1951). Shaw (1953) proposed a modification to the
model presented by lee and shafer .palmer presented the shear zone theory by allowing for

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variation in the flow stress for a work hardening material. Van Turkovich (1967) investigated
the significance of work material properties and the cyclic nature of the chip-formation process
in metal cutting .slip line field theory is widely applied in chip formation research and some
slip line field models are presented (usni, 1963: Johnson,1 970:Fang,N.2001).being
computationally successful, slip line field models do not agree well with experiment result due
to lack of knowledge of the high strain rate and temperature flow properties of chip material.
Through studying the chip flow in free oblique cutting, stabler presented a famous rule called
the stabler rule (stabler, 1951):

=Kkr (2-1)

Where the is the chip side flow angle, the kr is the cutting tool inclination angle, and K is
a material constant. This rule is applicable for free oblique cutting.

Another chip flow model is presented with the assumption that the chip flow is perpendicular
to the major axis of the projected area of cut. This model uses empirical substitution to
consider forces (colwell, 1954) i.e.

=tan-1 2rc d-d2 +f/2 d (1-cos Kr) (2-2)

d r
d/tan Kr+ r tan (Kr/2) +f/2 d (1-Cos Kr)
=tan-1 d r (3-3)
r
Where d is depth of cut, kr is insert lead angle, f is feed rate, and re is nose radius (see figure2-
2)

La
ter on the
groove

parameters will be defined along the side flow angle. Since colwells equation does not
consider the effect of the work-piece material. This model therefore will result in significant
error under particular conditions.
Okushima considered that chip flow is invariant with cutting speed and chip flow should be
the summation of elemental flow angles over the entire length of the cutting edge (Okushima,
1959).

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A chip flow model was represented by young in 1987, assuming stablers flow rule, with
validity

For infinitesimal chip width, and the direction of elemental friction forces summed up to
obtain the direction of chip flow (young 1987).

The above chip flow studies are shown in figure 2-3

Figure 2-3 chip Flow Models for Machining with a flat-faced Tool (jawahir 1998)

Ja w
ahir et al
(1988-

a)found that a chip also has another form of flow angle, which he called chip back flow
angle()show in figure (3-4).however in real machining condition the chip flows in 3-D space
with both side and back flow angles.

Figure
(3-4)
chip
Back
Flow
Angle

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CHIP CURL

Chip flow is only a part of chip space movement .To understand the chip movement
mechanism, it is necessary to study chip curl .chip curl has two basic modes: up-curl and side-
curl. Recently the third chip curl mode called lateral curl was found (fang, 2001).the chip up-
curl is much simpler than the other two kinds of chip curl. Therefore, the greatest achievements
have been in chip up-curl modeling. Chip side-curl is much more difficult than up-curl and
currently there are no applicable models of the chip side curl.

CHIP UP-CURL

The chip up-curl is chip that curves in the plane which is defined by chip flow direction and
perpendicular to the cutting edge. The up-curl curve is described with chip up-curl radius R 0
.Nakayama considered that when there is a buildup edge in the cutting tool, the part of the chip
that flows over the build up edge would come in contact with the tool rake-face, which brings
a bent moment to the chip (Nakayama, 1962-b) for the grooved tool, the chip breaking groove
can help chip curl (see figure3-5).

Figure3-5 Chip Up Curl Process With Grooved Cutting Tool (Li.Z1990)

The

following is the chip curl radius (Ro) equation given by jawahir et al (1988-e)

Ro =R (3-4)

Where R is the chip breaking groove radius. In this equation it is assumed that the chip back
flow angle is very large or the restricted contact length is small so that the chip flows through
the whole chip-breaking groove(figure3-6a).If the chip back flow angle () is small or the
restricted contact length is long ,the chip does not flow through the whole chip breaking
groove.in that case the up curl radius equation according to jawahir et al is

Wn
2sin

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Ro =Kch (3-5)

Where Kch is a constant determined by the chip material, Wn is groove width and is chip back
flow angle (Figure3-6b).

Figure 3-6 Chip Radii According to Jawahir (1988-e) Theory

Based on chip cutting tool geometry analysis, li et al (1990) presented a chip up- curl radius
equation where the insert rake angle was considered as the chip flow entrance angle in the
groove. Here the chip tool contact length on the groove body is taken into account.

Wn lf
Ro= 2sin 1-2 Wn cos n (3-6)

Where lf is the chip/tool contact length, and n is the rake angle.it is noticeable that this
equation is not affected by groove profiles, which are not necessary, a portion of the circle.
Also this equation is for insert grooves in which the back wall height is zero.

Zhou (2001-a) added the insert groove back wall height as shown in Figure 3-7 and formulated
this equation:

Wn2+h2+lf 2+2lf (-Wn cos n+h sin n)

Ro= (3-7)
2(Wn cos n+h sin n)

Where h is back wall height.

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Figure 3-7 Chip Up Curl Formation According to Zhou et al Theory (Zhou 2001-b)

CHIP SIDE CURL

Chip side curl (Rs) is the chip curl in the direction of chip width. The side-curl axis is
generally perpendicular to the chip bottom surface. The chip side curl is caused by difference
in the material flow speed along the chip width direction on the chips bottom surface (see
Figure 3-8).

Figure 3-8 Mechanism of Chip Side-Curl (Zhou 2001-b)

The chip side-curl radius has a critical influence on side curl dominated chip-breaking .the
main object of chip side curl research is to establish the model of the chip side curl radius.

Nakayama considered that the chip material had side flow, which leads to chip side-curl.
He also considered that the thicker the chip ,the greater chip material side flow therefor the
greater the chip side curl. He proposed the following side curl radius equation,

1 0.75 0.09 1 (3-8)

=
Rs bch hch k

Where bch is the chip width and hch is the chip thickness.(Nakayama 1990)

CHIP LATERIAL-CURL AND COMBINATION CHIP CURL

Chip lateral-curl was identified by Fang N (2001).It may appear in a very special condition
.there is no model built up for chip lateral curl yet. In real cases, the chip curl form is a
combination of the two basic curl forms: up-curl and side curl.

CHIP BREAKING CRITERION

As discussed in chapter 1, chip breaking has two basic modes: chip breaking by chip/work
surface contact or chip breaking by chip/tool flank surface contact. For chip breaking research,
we need to set up the chip braking criteria; for industry application, we need to find efficient
ways to break chips.

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The following is a summary of the two approaches of chip breaking research:

1. Material stress analysis-to find the chip-breaking strain B.

Research work by this approach includes:

Chip curl analysis(Nakayama,1962;li,1990)

Finite element Analysis or FEA(Kiamecki,1973;Lajczok,1980;Strenkowski,1985;etc)

2. Experiment-based work

This approach uses the database system established by fang and jawahir which is based on
fuzzy mathematical model for chip breakability assessments (FANG, 1990-a, jawahir, 1989).

This approach requires lots of time, money, and labor to establish the chip breaking prediction
database. With new work piece material, new cutting tools/lathe, and new machining methods
constantly coming out it is difficult to establish and maintain a chip breaking data base for
prediction.

Tool designers optimize their tool design based on many cutting tests. In the industry machine
process some special devices such as a rotating knife a high pressure gas fluid jet under
vibrating cutting tool are also designed to break the chip however the efficient and most
common way to break chips is to use chip breaking group/chip breaking and optimize
zoometric features in the cutting tools.

Presently there has been only limited success in the chip breaking criterion study. The
theoretical achievements fall behind industry reality and requirements.

Nakayama (1962-B) presented the most common chip breaking criteria up curl laminated
chips. Presently most research on chip breaking criteria are for two dimensional chip breaking.
The chip breaking criteria for three dimensional chip breakings needs further investigations.
Three dimensional chip breaking criteria cannot be established without a reasonable two
dimensional chip breaking model.

The finite element method has been applied in the chip breaking process analyses for plane
rake face and grooved tools for orthogonal machining and most recently for three dimensional
machining (kiamecki, 1973;Lajczok, 1980; Strenkowski, 1985, 1990). These analysis are
computational successful but their predictions do not agree with the experiments.

Nakayama chip breaking criteria is the most common. Therefore it is reviewed in detail.

Nakayama considers that when the actual chip fractures strain () is smaller than the tensile
strain of the chip (B), the chip will break. It is noted that e is proportional to the ratio of chip
thickness and chip curl radius i.e. (Li. Z 1990)
hch
R0
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B (2-9)

.Where hch is the chip thickness; R0 is the chip up-curl radius.

Nakayama consider that a chip flows out with up-curl radius. R0, and then is blocked by
the work piece surface of the cutting tool. With the chip material continuously flowing out the
chip curl radius will be increasing continuously. When the chip reaches up curl radius RL
Where the chip actual fracture strain e is smaller than the chip strain B. The chip will break.

When chip cross-section shape is rectangle B can calculated by the following equation.

hch 1 1
B=2 R0 RL (2-10)

Otherwise, the above equation can be written as Nakayama (1962-b):

1 1
B= ch hch (2-11)
R0 RL

Where ch is cross section shape coefficient; and hch is the chip thickness.

LIs Work on Chip-Breaking:

Developing a reasonable chip breaking criterion is the prerequisite for establishing an

applicable chip breaking predictive model. However the extreme complexity of the chip
breaking process makes the theoretical analysis and modelling of chip breaking very difficult.
Based on Nakayamas work and chip breaking limits theory, through chip curl analysis Li
(1990) presented a new semi-empirical chip breaking prediction model.

Since it is the basis of the chip breaking prediction models developed in this research, it will be
reviewed in detail in the following section. To better understand the model, first the chip
breaking chart is introduced.
Chip breaking chart

Below is the chip breaking curves and chip type classifications based on observations from
previous study involving a large number of experiments.

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 (a) (b

Figure 3-9 Typical chip Breaking Charts (Li, 1990)

The graphs show that there are critical feed rates and critical depth of cuts. When the
depth of cut is greater than the critical depth of cut and the feed rate is greater than critical

feed rate, the chip will break. Otherwise a long chip will be produced. For specific work piece
materials, cutting tools and cutting speed, the chip breaking chart is consistent. Generally the
chip breaking curve can be divided into three typical parts (Figure 3-9a) up curl dominated
chip breaking region AB, side curl dominated chip breaking region CD, and transitional region
BC. Because of complicated nature of chip in BC, the curve in CD and AB only in analysed
and the relevant equations are detailed in this chapter.

Side Curl Dominant Region CD

The region CD of the chip breaking curve shown in figure 3-10a includes side curl
dominated chip formation and breaking processes. Side curl chip is the chip curl in the
direction of the chip width. The side curl axis is generally perpendicular to the chips bottom
surface (see figure 3-7). This region shows a complex 3-D chip curling. On each side of the
limit, the broken area is mainly of side-curved spiral type continuous chips.

UP-Curl Dominant Region AB

In the region AB of the chip-breaking curve shown in Figure3-9a, The lowest point B,
is the minimum or critical feed rate. This region is primarily a straight line with a slope and
with regard to Figure 3-9, can be analysed as a 3-D chip up curling dominant process. So the
definition of up curl chip is the chip curl in the chip thickness direction, the axis of chip curl
approximately parallels the chip/cutting tool rake face detachment line.

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Based on Nakayamas work and chip breaking limits theory, through chip curl analysis, Li
(1990) presented a new theoretical and semi-empirical chip breaking model.

Since it is the basis of the chip breaking models developed in this research, they are reviewed
in detail in the following parts.

Theoretical Analysis method

Semi-Empirical predictive method

Theoretical Analysis of Critical Feed Rate and Depth of Cut

As it was explained in chip breaking chart: The chip will always break when the depth of
cut is greater than the critical depth of cut (dcr) and the feed rate is greater than the critical feed
rate (fcr) Otherwise, the chip will not break.

In Nakayamas model (Equation (3-11), for up curl dominated chip breaking region, the chip
thickness (hch) can be calculated as:

F sin kr
hch= Ch (3-12)

Where kr is the insert lead angle Ch is the cutting ratio.

Substituting hch in to equation (3-11) the following equation is established for critical feed rate
(fcr):
b Ch KR Ro
fcr = (3-13)
ch sin Kr

Where KR is the coefficient related to the chip radius breaking:

KR=RL/ RL- Ro (3-14)

When f > fcr the chip will break. Similar to f a critical depth of cut (dcr) can be defined for
the side-curl-dominated chip breaking region (see Figure3-11). The equation of d cr for two
dimensional grooved inserts is as follows (Li, 1990):

B Rs cos 1 r For dr
dcr = (3-15)
2

57.3 B Rs cos
dcr = Cos - r for d<r (3-16)
r

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Where Rs is the radius of side curl chip (Equation (3-9)); and are chip cross sectional
related parameters and r is the insert nose radius.

In critical depth of cut equations insert nose radius is the major parameter that affects
critical depth of cut.

Figure Chip Flow of Side-Curl of Side Curl dominated -Type Chip (Zhou 2001-b)

Although in practical, the critical depth of cut is affected by grove parameters (Zhou 2001-b)
but the groove parameters have no role in chip side curl formation and chip radius dimension.
In this study more concentration will be given on up curl dominant chip formation, which
explicitly affected by insert specifications.

Equation (3-13) does not satisfy real machining conditions, which chip formation occurs in 3-
D with 3-D groove. Therefore in this thesis critical feed rate equation (Equation (3-13)) will be
improved to 3-D with 3-D groove. As well in conditions that the depth of cut is smaller than
the nose radius (e.g. d<r), critical feed rate (fcr) will modified.

Final result /conclusion/expected outcomes

The previous efforts on controlling, classifying, and predicting chips are the first steps
toward understanding the chips to reduce their impact as a containment; however ,previous
research does not consider how the remaining chips will affect the function of the final part
,assuming that once the machining operation is complete, any remaining chips can be easily
removed .As a first step to address this issue , it was desired to discover which of the following
have the greatest impact on chip formation: feed ,speed ,lubrication, tool geometry or
DOC.These parameters were chosen because they are easily varied in an established

Page 19
manufacturing configuration .From this information ,trends of chips formation may be
developed for use in industry to control chip geometries and sizes.
First of all a single point cutting tool of HSS material of desired tool geometry i.e. rake angle
,inclination angle, clearance angle, cutting edge angle, nose radius etc. Was made with the help
of 3-d grinding machine.
After that work piece of mild steel was fixed properly in the chuck of automatic lathe machine
while the tool was fed past the work piece in a direction parallel to the axis of rotation .thus the
cylindrical surface was generated and chips were produced under different cutting parameter
i.e.feed,speed,DOCetc.
Now chips were collected and the natures of chips were observed using tool microscope,
micrometre & the image analyser.

CHIP CLASSIFICATION

It was noticed that given a single set of cutting parameters (feed, speed, DOC etc)up to
different chip sizes or geometries were produced .It was seen that slide variations in the
machine vibration or the material properties could produce variations in the chip.

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 To accurately represent the output of each experiment machining operation the chips were
divided in to categories by size & shape

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REMAINING ACTIVITY IN THE COMPLITION OF THE PROJECT:-

Experiment on the workshop with cutting tool having the following difference rake
angle and cutting speed.

Rake angle Cutting speed

5 60
5 60
10 50
10 40
15 90
15 90

Final report with expected out comes and result.

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 COMMENT OF THE LOCAL SUPERVISOR ON THE PERFORMANCE OF THE STUDENT IN PROJECT WORK.

Comments from Local Guide

EVALUATION

PROJECT WORK PROGRESS EVALUATION (Please put a tick ( ) mark in the appropriate box)

EC No. Component Excellent V. Good Fair Poor

1. Synopsis
2. Mid-Semester Progress

Name N.KRISHNA RAO

Qualification M TECH (MAINTENANCE ENGG)
AGM-MAINTENANCE
Designation & Address
AT-ARYA IRON AND STEEL COMPANY,BARBIL ,ORISSA

Phone No. 09617779964

Email Address Krishnarao.nalla@gmail.com

Signature

Date 28/09/2010

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