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Design of Adjustable Chip Breaker For PCD Turning Tools
Design of Adjustable Chip Breaker For PCD Turning Tools
PII: S0020-7403(19)33272-2
DOI: https://doi.org/10.1016/j.ijmecsci.2019.105411
Reference: MS 105411
Please cite this article as: Maochao Wu , Aibing Yu , Qiujie Chen , Yanlin Wang , Jiandong Yuan ,
Lei Sun , Jianying Chi , Design of Adjustable Chip Breaker for PCD Turning Tools, International Jour-
nal of Mechanical Sciences (2019), doi: https://doi.org/10.1016/j.ijmecsci.2019.105411
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Maochao Wu, Aibing Yu*, Qiujie Chen, Yanlin Wang, Jiandong Yuan, Lei Sun, Jianying Chi
Abstract: To obtain better chip breaking effect for most cutting parameters, a chip breaker which position on rake
face of tool can be adjusted is designed and analyzed. According to the structure and installation features of the
PCD insert, structure of adjustable chip breaker is designed. Through finite element simulation and cutting
experiments, the influences of chip breaker parameters on the radius of chip curl curvature were analyzed to
determine the parameters of chip breaker. Forces on chips and the chip breaking processes of PCD tool with chip
breaker were analyzed. The geometric relationships between chip breaker and chip were established. According to
the geometric relationship and the chip breaking criterion, the formulas of three chip breaker parameters were
deduced. A design method for chip breaker parameters of PCD tool was proposed. The research results show that
the radius of chip curl curvature decreases as the inclination angle increases and decreases as the position
parameter decreases. There is a threshold for both inclination angle and the position parameter of the chip breaker,
and if the threshold is exceeded, severe noise and chip build-up will occur. If the contact point between the chip
and the chip breaker is located in the selected segment of chip, the extrusion force between the chip and the chip
breaker will increase as the chip grows, which can cause the chip to crack and break easily. The influence
mechanisms of inclination angle and the position parameter of chip breaker on chip curling are obtained. A simple
set of equations are derived for designing chip breaker parameters, including inclination angle, position parameter
and height. A design method for chip breaker parameters of PCD tool is presented. The application of the chip
breaker can expand the chip breaking range of cutting parameters for PCD tools.
1 Introduction
PCD cutting tools have been widely used in high-speed precision machining of aluminum alloys [1, 2],
titanium alloys [3, 4] and non-ferrous matrix composites [5] in the automotive, aerospace, defense, and 3C
industries. However, there is one problem that the chips are difficult to be broken during the processes of cutting
aluminum alloy and titanium alloy materials for PCD tools [6]. If the chips cannot be broken, the continuous chips
will tend to tangle with workpiece or cutting tool in machining processes. This chip winding phenomenon may
cause some serious problems such as reducing the surface accuracy of the workpiece [7], shortening the tool life and
endangering the safety of workers. Usually, machine needs to be stopped periodically to remove the tangled chips,
but frequent downtime will affect the automation process and production efficiency [8]. Nowadays, chip breaking
has become one of the key factors affecting the automation production [9, 10]. If the chips can be broken into
appropriate lengths using effective chip breaking technology, the production efficiency can be improved, the
production cost can be reduced and the process of automated production can be promoted while ensuring the quality
of the workpiece.
At present, the main means of chip breaking are to fabricate chip breaking groove or raised chip breaker on the
rake face of the turning tool. Chip breaking groove is commonly used to break the chips for the cemented carbide
and high speed steel tools [11]. However, for PCD tools, it is difficult to machine chip breaking groove on the tool
rake face from the aspects of material forming and machining processes. For example, Silva et al points out that
there is no PCD chip breaking groove forming process at present [12], and Elkaserer et al shows that it is impossible
to determine the geometry of the chip breaking groove prior to the brazing stage during the production process of
brazed PCD inserts [13]. From the viewpoint of machining, laser processing and EDM are usually used to process
the chip breaking groove on the rake face of PCD tools after brazing. However, it is difficult to machine specific
geometries on the tool surface due to the characteristics of PCD material [14]. For example, if laser processing is
used to machine the chip breaking groove, the PCD tool is prone to be heated to generate defects such as
graphitization, cracks and pores, due to the poor heat resistance of the PCD material [15-17]. And these thermal
damages will reduce the performance of PCD tools. If the chip breaking groove is machined by EDM, the electrode
will be damaged and the surface roughness of the workpiece will be poor, due to the poor conductivity of the PCD
material [18]. In short, the problems of low processing efficiency, high cost and surface processing damage limit the
wide engineering application of PCD cutting tools with chip breaking groove in a certain extent.
In addition, the strength of the PCD insert and cutting edge will be reduced after the PCD tool rake face is
grooved due to the poor toughness of the PCD material. So, the PCD tool is prone to loss the use value. If the chip
breaker is used for chip breaking, the cutting edge can be protected to a large extent. In this paper, an adjustable chip
breaker is designed, which can achieve good chip breaking effect under various cutting parameters. The influence of
the chip breaker parameters on the radius of chip curl curvature Rc is analyzed by the finite element simulation
method. The range of the chip breaker parameters is determined through the calculation of geometrical relationships
and cutting experiments.
Fig. 1 Schematic diagram of chip breaker parts and PCD tool structure
(a)Assembled structure (b)Assembled photo
Significant findings on chip flow have been done by Stabler [19], Russell [20] and Young [21]. Using a
cutting edge chord method, Colwell [22] showed the chip flows approximately perpendicular to this chord
representing the major axis of the projected area of cutting. The model of Okushima and Minato [23] showed chip
flow is summation of elemental flow angles over the entire length of the cutting edge. On this basis, Hu et al
shows that the equivalent cutting edge is equivalent to the part of the cutting tool actually involved in the cutting
processes, and the chip flow direction is perpendicular to the equivalent cutting edge [24]. According to related
research jobs, the position of equivalent cutting edge can be determined [25, 26]. As shown in Fig. 3(a), if the chip
breaker is parallel to the equivalent cutting edge, the chip will flow vertically to the chip breaker. Fig. 3(a) is the
tool reference plane through point A. In the Fig. 3(a), point O is the center of nose radius of PCD insert tool, point
A is the intersection of the cutting edge and the straight line passing through point O and perpendicular to the
equivalent cutting edge. The chip breaker can promote the upward curling of the chip and cause the chip to flow to
the surface of workpiece. When the radius of chip curl curvature Rc is small enough, the chip can be broken, or
when the chip hits the workpiece, the strain of chip will increase instantaneously and cause the breaking of chips,
as shown in Fig. 3(b). The structure parameters of chip breaker, such as inclination angle θ, height H and position
parameter W, can affect the radius of chip curl curvature Rc. So, the range of these three parameters needs to be
determined in this study.
Some researchers have studied the structure of the chip breaking groove, such as Fang [27], Worthington and
Redford [28] and Kaldor [29]. According to the function of the chip breaking groove, the structure of chip
breaking groove can be divided into two parts, part A and part B, as shown in Fig. 4. The function of part A is
equivalent to increasing the rake angle of turning tool, and the chip will be led into the chip breaking groove to
promote chip curling. However, the part A of chip breaking groove may reduce the strength of PCD cutting edge.
The part B can further promote chip curling to reduce the radius of chip curl curvature. It is part B that causes the
chip to break. If a chip breaker is used to break chips, this is equivalent to using the function of part B of chip
breaking groove, and the disadvantage of reducing the strength of the cutting edge in part A can be avoided. The
chip breaker can protect PCD insert tool from chipping of cutting edge. In Fig.4, we select the commonly used
dimensional parameters of part B of chip breaking groove of commercially available cemented carbide as the
initial design reference of chip breaker parameters of PCD insert tool. Moreover, the finite element simulation
technology is used to adjust the parameters of chip breaker to achieve good chip breaking effect of PCD insert
tool.
Chemical element Si Fe Cu Mg Mn Zn Ti Cr
wt. % 0.08 0.14 1.4 2.4 0.03 5.4 0.03 0.21
(a) Chips produced by PCD tools with different inclination angle of chip breaker
(b) Relationship between radius of chip curl curvature and inclination angle of chip breaker
Fig. 8 Effect of inclination angle of chip breaker on the radius of chip curl curvature
(a) Chip winding (b) Chip piled (c) Workpiece scratched surface
Fig. 9 Turning experimental results of PCD tool with different θ
(a) Chips produced by PCD tools with different position parameter of chip breaker
(b) Relationship between radius of chip curl curvature and position parameter of chip breaker
Fig. 10 Effect of position parameter of chip breaker on the radius of chip curl curvature
The radius of chip curl curvature Rc is affected by both the inclination angle θ and the position parameter W
of the chip breaker. The radius of chip curl curvature Rc will be decreased as the inclination angle θ increases or
the positional parameter W decreases. But, there exists a threshold value for θ and W. When W and θ reach their
threshold value, the normal cutting process cannot be carried out. In order to explain this phenomenon, we analyze
the force of chip during cutting processes.
During the cutting process, the chip will slide along the tool rake surface. As shown in Fig. 13 (a), the chip
begins to curl as the chip slips to a certain distance which is the tool-chip contact length Lf. Balaji and Ghosh
proposed that the chip flow direction can be affected by restricting the tool-chip contact length [7]. What is more,
from the study of Stevenson [41] and Madhavan [42], we can know if the friction between the tool and chip is
reduced, the tool-chip contact length Lf will be increased, and the degree of curl of chip will be reduced. The same
conclusion was gotten that high friction on the tool rake face leads to an increase in chip curvature by Shi and
Ramalingam [43]. While PCD tool has a very low coefficient of friction, the tool-chip contact length and the
radius of chip curl curvature Rc will be increased without any chip breaker measures. In Fig. 13 (a), point A is the
starting point of chip curling, point B is the end of chip point. Both point A and point B are located on the center
line of the chip. In the absence of chip breaking measures, the chip will flow along the trajectory of B0. If a chip
breaker is applied, the chip will change its’ flow direction and flow along the trajectory of B 1. The chip breaker
will cause chips to curl further. In order to measure the degree of chip curling, an angle β between the straight line
AB and tool rake face is used as an evaluation index. According to the trajectory of B0, it can be seen that if the
position parameter W of chip breaker increases, the degree of chip curling when the chip hits the chip breaker also
increases. In other words, β increases as W increases.
As shown in Fig. 13(b), when the chip hits the chip breaker, the force on chip can be decomposed into two
components, force Fr perpendicular to chip breaker and friction force Ff. Taking the direction of straight line BA
as the x-axis, we establish a rectangular coordinate system. Fr and Ff are respectively decomposed along the x and
y directions. Let Fx be the resultant force in the x direction, let Fy be the resultant force in the y direction. From
Fig. 13(b), we have
𝐹x = 𝐹r1 + 𝐹f1 (3)
𝐹y = 𝐹r2 − 𝐹f2 (4)
Where,
𝐹r1 = 𝐹r sin(𝜃 − 𝛽) (5)
(a) Internal stress (b) Internal strain (c) Crack generation (d) Motion track of chip
𝜀 p = (11)
1
1 1 (12)
𝜀 = ( − )
1 2
In addition, Nakayama proposed that the chip will be broken when the bending strain εwb reaches to the chip
breaking strain εf, εwb≥εf [48]. Equation can be expressed as
1 (13)
𝜀 = ( − ) 𝜀f
1 2
Where, αch is the chip thickness, r1 is the radius of chip curl curvature after the chip flows out through the
chip breaker, r2 is the radius of chip curl curvature when the chip is reversely broken, εf is the chip breaking strain,
εwb=εwp+εwnb.
From Eq. (13), the smaller the value of the radius of chip curl curvature r1 is, the bigger the chip bending
strain εwb is, and the more easily the chip breaks. The moment Mr can promote further curling of the chips to
reduce r1. So, if the moment Mr becomes bigger, chips will be easier to break. Since Fr is proportional to M r, the
bigger the Fr is, the more easily the chip breaks.
Fig. 16 Forces and moments on chip
According to the above analysis, we can know that chip breaker exert a force Fr on chip during the cutting
processes. The force Fr can affect the cracking and breaking of chip. However, Fr is affected by the inclination
angle of chip breaker θ. In order to make the chip easy to break, it is necessary to design the range of inclination
angle θ to increase the force Fr.
4.3.2 Range of the inclination angle θ
Fig. 17 (a) is the simulation of chip flow trajectory. Firstly, the chip curls naturally. When the chip hits the
workpiece surface, the force Fn is generated. The Fn will change the movement direction of the chip and increase
the value of radius of chip curl curvature. Comparing the chip position at different time, we can find that the
change of the chip position mainly occurs in segment C, while little change in segment D of chip occurs, as shown
in Fig. 17 (b). Then, we can measure the values, θb1=30° and θb2=60°. Therefore, if the contact point between the
chip and the chip breaker is located in the selected segment C of chip, as shown in Fig. 17 (b), the extrusion force
Fr between the chip and the chip breaker will increase as the chip grows, which can cause the chip to crack and
break easily.
∠𝐴 𝐹 = ∠𝐴 𝐺 + (16)
∠𝐴 𝐺 = (17)
∠𝐹𝐸𝐴 = (18)
Substituting Eqs (15), (16), (17) and (18) into Eq. (14) , we have
𝜃= 1 + (19)
According to above analysis,the contact point E between chip and chip breaker shown in Fig.18 should be in
the selected segment C in Fig. 17(b). Where θb1 =30° and θb2 = 60°, then α1∈ (60°, 90°). Substituting α1 into Eq.
(19), we can get θ∈(60° + γo , 90° + γo). From the above analysis in seciton 4.2.1, we have θ < 75°, then θ∈( 60°
+ γo , 75°). If the value of parameter θ is within above range, there will be a higher extrusion force Fr, which can
cause chip to break and flow out smoothly. For example, when rake angle γo =0, according to Eq. (19), the
parameter θ value that satisfies the chip breaking condition should be θ∈(60°, 75°). In Figs. 11 (a) and (b), chips
can be broken effectively by the PCD tool with chip breaker which pareameters are γo=0, θ=65°, W=1.5 mm and
H=5 mm. Through above experimental results, the reasonable range of parameter θ can be proved.
Fig. 18 Geometric relationship for solving parameter θ
In order to further verify reasonable range of parameter θ ∈(60°, 75°), cutting experiments were carried out
with the PCD tool with rake angle γo =0 and chip breaker parameter θ=45°, 50°, 55° and 60°, respectively. The
other parameters of the chip breaker were as follows: W = 1.5 mm and H=5 mm. Cutting parameters were as
follows: v c=800 m/min, ap=1 mm and f=0.2 mm/r. The experiment results are shown in Fig.19. When θ = 60°, the
chip can be broken normally during cutting operations, and chips are mostly C-type chips. When θ = 55°, the chip
breaking is in an unstable state. In Fig.19 (b), short spiral chips are generated, and sometimes long spiral chips are
formed which can not be broken. For θ=50° and 45°, continuous chips are randomly and disorderly wound around
the surface of workpiece and the cutting tool. According to above experimental results, if the chip can be broken
into C-type chips effectively, the inclination angel of chip breaker θ should not be less than 60°. By observing the
degree of the chip curling, we can find that the radius of chip curl curvature Rc gradually decreases as pareamter θ
increases. This observation is consistent with the simulated results shown in Fig. 8 (b).
𝜃1 1 (21)
𝜀f
̂ shown in Fig. 20. We have 𝜃1
Where, θ1r1 is the length of arc when the chip is broken, which is arc 𝐸𝑄 1
̂.
= 𝐸𝑄
̂
𝐸𝑄
𝑅as (22)
Shinozuka et al [49] measured the size of chips and found that the ratio of the chip arc length 𝐸𝑄 ̂ to the chip
thickness ach is always less than a fixed value. The above research results can verify the Eq. (22). Therefore, we can
use Eq. (22) to predict chip breaking and to design a reasonable position parameter W of chip breaker. In Fig. 20,
point D is the tangent point between chip and rake face of tool, point E is the tangent point between chip and chip
̂ is the
breaker, AY is a horizontal straight line, SZ⊥AY, Lf is tool-chip contact length, ach is chip thickness, and 𝐸𝑄
arc length of chip from point E to point Q.
𝐴1 𝐴 = (25)
𝐴𝐴1 (26)
𝐴1 𝐴𝑄 = arc cos
In order to calculate angle ∠A1AQ, it is necessary to solve line segment AA1 and the outer radius of chip curl
curvature r in Eq. (26). From Fig. 20, we have AA1=SZ, SZ=SD+DZ, then the calculation formula of AA1 is
AA1=SD+DZ (27)
where,
𝐷 = f cos − (28)
𝑆𝐷 = sin 𝑆𝐴𝐷 (29)
and
(30)
𝑆𝐴𝐷 + 𝑆𝐷𝐴 =
(31)
𝑆𝐷𝐴 + =
where,
𝐷𝐹 = − f (34)
𝐷𝐹𝐸 = − 𝜃 (35)
Substituting Eqs. (34) and (35) to Eq. (33), we have
−𝜃 (36)
=( − f ) tan
Substituting Eqs. (19), (25) and (39) into Eq. (24), we have
−𝜃 (40)
f cos − +( − f ) tan sin
𝜃1 = − arc cos −𝜃+
−𝜃
( − f ) tan
Iqbal et al [50] derived a formula for calculating the tool-chip contact length Lf
f = , (1 − tan ) + sec - (41)
(42)
where =
= sin 𝜅r (43)
Substituting Eqs. (23), (33), (40), (41), (42) and (43) into Eq. (22), we have
( 𝜅 , ( ) -) , ( ) - 𝜅
( 2 s 𝜅 , (1 ta ) s -) ta ( 𝑜 )
( 𝜅 , ( ) -)
𝑛𝜅
𝑅as (44)
3
Let sin 𝜅r , (1 − tan ) + sec - = a0 , tan = 0 and −𝜃+ = c0 , then we have
2 2
𝑅 sin𝜅r (45)
+ a0
a cos − sin 𝜅r
0 *c0 − arc cos (sin + 0 )+
0( − a0 )
For the convenience of calculation, we simplify the Eq. (45) to Eq. (46). The simplification process of Eq. (45) is
shown in the appendix.
where, k is the correction factor, and we set k=0.907. The calculated process of correction factor k is also shown in
the appendix.
If position parameter of chip breaker W meets Eq. (46), the chip can be broken. For a given feed rate f*,
inequation W≤Wf* can be obtained according to Eq. (46). And according to our analysis in section 4.2.2, we have
W>Lf*. So, we can give the range of parameter W for effective chip breaking, Lf* <W ≤ Wf*. Fig. 21 is a schematic
diagram of range of parameter W for effective chip breaking. For example, given f=0.2 mm/r, ap=1 mm, θ=65°, H=5
mm. The other relevant parameters are γo=0 and κr =110°. Chip compression ratio ξ can be calculated according to
Eq. (42). We get an average value ξ=0.78 based pre-experiments. According to the study of Liu et al [51], we can
calculate the fracture strain εf of the 7075-T651 aluminum alloy, that is εf =0.109. So, we can have Ras=29, a0=3.31,
b0=1.57 and c0=3.58. According to Eq. (46), we can obtain the range of parameter W for effective chip breaking,
0.67 mm<W≤1.67 mm. Our results shown in Fig. 11 can provide a proof for this range of parameter W. In Fig. 11,
we set W=1.5 mm. Since 1.5∈(0.67, 1.67), Eq. (46) can be verified for f=0.2 mm/r. In order to further verify Eq.
(46), experiments with other feed rates were conducted, and results are listed in Table 4.
f = − 𝐴𝐶 (47)
where
𝐴𝐶 = cos 2 (48)
α2 in Eq. (48) can be calculated based on the quadrilateral ADFE
𝐷𝐹𝐸 = −𝜃 (51)
𝐹𝐸𝐴 = (52)
Substituting Eqs. (50), (51) and (52) into Eq. (49), we have
2 =𝜃 (53)
Substituting Eqs. (36), (41), (48) and (53) into Eq. (47), we have
−𝜃 (54)
f =( − sin 𝜅r , (1 − tan ) + sec -) tan (1 − cos 𝜃)
In section 4.2.2, we have proved that the chip breaker with parameters θ=65°, W=1.5 mm and H=5 mm enabled
effective chip breaking. The other relevant parameters are as follows: f=0.2 mm/r, ap=1 mm, γo=0, κr=110° and
ξ=0.78. According to Eq. (54), the effective height of chip breaker can be calculated as hef=0.31 mm. Since H=5
mm>hef=0.31 mm, the theoretical calculation results are satisfied.
Through the above analysis of the effect of the chip breaker on chip breaking, we can summarize a design
method for chip breaker of PCD tool. Firstly, the calculation method of inclination angle θ is obtained in
consideration of the occurrence of chip cracks. Then, according to the criterion of chip breaking, the calculation
method of position parameter W is obtained. Finally, to ensure that the chip can touch chip breaker, the calculation
method of height H of chip breaker is obtained. So, we can get a simple set of equations for parameter design of chip
breaker of PCD tools, which includes Eqs. (19), (46) and (54).
The shape of chip breaker is determined by parameters θ and H. In Eq. (19), parameter θ is affected by the rake
angle of cutting tool, so the value of parameter θ can be determined based on rake angle of cutting tool. Given range
of the cutting parameters, the maximum effective height of chip breaking hefmax can be calculated by Eq. (54). The
height of chip breaker H only needs to satisfy H>hefmax. So, if cutting parameters are adjusted, the shape of chip
breaker does not need to be changed. We only need to adjust the position parameter of chip breaker W according to
Eq. (46) to obtain chip breaking under different cutting parameters.
In this study, an adjustable chip breaker is designed to expand the chip breaking range of cutting parameters for
PCD tools. Usually, most of the chip breaking conditions mainly include two types, one is that the chip touch the
workpiece, the other is that the chip touch tool shank. However, only first condition is considered in this study. We
set the chip breaker parallel to the equivalent cutting edge to allow chip to flow onto the workpiece. If a reasonable
angle between chip breaker and equivalent cutting edge is set, the chip may flow to tool shank. So, it is necessary to
investigate the influence of the angle between chip breaker and equivalent cutting edge on direction of chip flow and
chip breaking in further study.
5 Conclusions
An adjustable chip breaker is designed according to the structure and installation features of the PCD insert.
The position of the chip breaker on rake surface can be adjusted according to the variation of cutting parameters.
The influence mechanisms of inclination angle and the position parameter of chip breaker on chip curling are
obtained. There is a threshold for both inclination angle and the position parameter of the chip breaker. The
selected segment of chip which can be cracked and broken easily is determined. A simple set of equations are
derived for designing chip breaker parameters, including inclination angle, position parameter and height. A
design method for chip breaker parameters of PCD tool is presented. The application of the chip breaker can
expand the chip breaking range of cutting parameters for PCD tools.
Acknowledgements
This study was supported by National Natural Science Foundation of China (Grant No. 51875294) and
Ningbo Natural Science Foundation (Grant No. 2018A610153). This study was also sponsored by K.C. Wong
Magna Fund in Ningbo University.
Author statement
Maochao Wu: Conceptualization, Methodology, Software, Investigation, Data curation, Validation, Formal
Aibing Yu: Conceptualization, Methodology, Formal analysis, Writing - review & editing, Supervision,
Qiujie Chen, Yanlin Wang, Jiandong Yuan, Lei Sun, Jianying Chi : Methodology, Investigation, Data curation,
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Appendix
In Eq. (45), position parameter W appears on both sides of formula, especially, position parameter W is in the
arccosine function. So, it is not easy to calculate position parameter W. The Eq. (45) is
𝑅 sin r
+ a0
a cos − sin (A1)
0 *c0 − arc cos (sin + 0 r
)+
0( − a0 )
3
arc cos =2− − 6
+ ( ) 2
− (A3)
The right side of Eq. (A2) can be approximately expressed with the Taylor’s formula (A3). Then we get
Hence,
3
In section 4.3.3, we have let −𝜃+ = c0 . So, c0 − 2 + sin . According to Eq. (A1), we can know
2
In order to calculate the accuracy of Eq. (A6), we compared the calculated results of Eqs. (A1) and (A6) as
shown in Table A1. It can be seen that the calculated results of Eq. (A1) is smaller than those of Eq. (A6).
Table A1. The range of W according to the calculation results of Eq. (A1) and Eq. (A6)
In order to improve the calculation accuracy of Eq. (A6) and to reduce the error between Eq. (A6) and Eq.
After above simplification process, we can get the Eq. (46), which is Eq. (A7) in Appendix.
In Table A1, the maximum error between the calculation results of Eq. (A1) and Eq. (A6) is 9.3%. So, we set